This procedure covers the removal and replacement of the ignition lock cylinder on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including disassembly of the steering column covers and proper installation of the new cylinder.

Warnings

Tools required

Parts

• Ignition lock cylinder assembly × 1 — Use OEM specification
• Steering column cover clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn ignition to OFF position and remove key
3. Disconnect negative battery terminal and wait minimum 3 minutes for airbag system to discharge
4. Adjust steering wheel to lowest and fully extended position for access
5. Place protective covering over driver's seat to prevent damage from tools

Procedure

1. 1

   Remove lower steering column cover
   Locate and remove the Phillips screws securing the lower steering column cover (typically 2-3 screws on underside). Gently pull the lower cover down and away from the column, releasing any retaining clips. Set cover and screws aside in organized manner.
2. 2

   Remove upper steering column cover
   Remove the screws securing the upper steering column cover (typically 2 screws at rear of cover). Carefully separate the upper cover from the column, being mindful of any wiring harness clips attached to the cover. Disconnect any electrical connectors if present and remove upper cover completely.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect ignition switch connector
   Locate the ignition switch electrical connector on the side of the ignition lock cylinder housing. Press the locking tab and carefully pull the connector straight off the switch. Note the orientation for reinstallation.
4. 4

   Access lock cylinder release mechanism
   Insert the original key into the ignition lock cylinder and turn to the ACC (accessory) position. Locate the small release hole or slot on the lock cylinder housing, typically on the underside or side of the cylinder body. Use a flashlight to clearly identify the release pin location.
   ℹ️The cylinder must be in ACC position for the release mechanism to align properly
5. 5

   Release and remove old lock cylinder
   While holding the key in the ACC position, insert a small pick or awl into the release hole and press the release pin firmly. While maintaining pressure on the release pin, gently pull the lock cylinder straight out of the housing using the key as a handle. If cylinder does not release, verify key is in correct position and release pin is fully depressed.
   ⚠Do not twist or rock the cylinder while removing as this can damage the housing
6. 6

   Inspect cylinder housing
   With the old cylinder removed, inspect the housing bore for any debris, damage, or wear. Clean the housing with a shop towel if necessary. Check that the ignition switch actuator inside the housing moves freely and returns to the OFF position.
7. 7

   Prepare new lock cylinder
   Remove the new ignition lock cylinder from packaging. Insert the new key into the cylinder and verify smooth operation through all positions (LOCK, ACC, ON, START). Ensure the cylinder is in the ACC position before installation.
   ℹ️New cylinder should come with 2 keys; test both keys before installation
8. 8

   Install new lock cylinder
   With the new key inserted and turned to ACC position, align the lock cylinder with the housing opening. Ensure the cylinder actuator tab aligns with the slot in the ignition switch. Push the cylinder straight into the housing until it clicks and seats fully. You should hear and feel a distinct click when the retention mechanism engages.
9. 9

   Test lock cylinder operation
   Verify the new cylinder operates correctly by rotating the key through all positions: LOCK, ACC, ON, and START (without battery connected, steering lock should engage and release). Ensure the key can be removed only in the LOCK position and that the cylinder does not pull out when tested gently.
10. 10

    Reconnect ignition switch connector
    Align and firmly press the ignition switch electrical connector onto the switch terminals until the locking tab clicks into place. Gently tug on the connector to verify it is fully seated and locked.
11. 11

    Reinstall upper steering column cover
    Position the upper steering column cover over the column, ensuring all wiring is routed properly and not pinched. Align the cover halves and install the retaining screws. Torque screws to specification using a torque wrench.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
12. 12

    Reinstall lower steering column cover
    Align the lower steering column cover with the upper cover and column. Press firmly to engage all retaining clips. Install the lower cover screws and torque to specification. Verify all cover panels are flush and properly seated.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
13. 13

    Reconnect battery and initialize system
    Reconnect the negative battery terminal. Turn the ignition to ON position (do not start engine) and verify all dash warning lights illuminate normally. Check that power windows, radio, and other accessories function correctly. Clear any stored diagnostic codes if necessary.

Reassembly

1. Ensure all steering column covers are properly aligned with no gaps or misalignment
2. Verify all electrical connectors are fully seated and locked
3. Confirm all screws are torqued to specification and none were left out
4. Test steering wheel tilt and telescoping functions to ensure covers do not interfere

Verification

• With engine off, verify key operates smoothly through all ignition positions (LOCK, ACC, ON, START)
• Confirm key can only be removed in LOCK position
• Start engine and verify normal operation with no warning lights related to ignition system
• Test that steering wheel lock engages when key is removed and disengages when key is inserted
• Verify all accessories (radio, windows, climate control) function normally
• Check that both keys operate the new cylinder correctly
• Inspect steering column covers for proper fit with no rattles or loose components

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