This procedure covers the removal and replacement of the ignition control module (ICM) on the 2016-2024 Hyundai Tucson 2.5L I4 AWD engine, which controls ignition timing and coil firing order.

Warnings

Tools required

Parts

• Ignition control module × 1 — Use OEM Hyundai/Kia part number
• Engine cover clips (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure engine is completely cool to the touch
3. Disconnect negative battery terminal and wait minimum 3 minutes
4. Remove engine cover by pulling upward on front edge to release clips
5. Photograph or label all electrical connectors for proper reassembly

Procedure

1. 1

   Access ignition coil assembly
   Locate the ignition coil pack assembly on top of the engine. On the 2.5L I4, individual coils are mounted directly above each cylinder. The ignition control module is typically integrated into the main coil harness connector or mounted on a bracket near cylinder 1 or 2.
2. 2

   Disconnect coil harness connectors
   Press the locking tab on each ignition coil electrical connector and pull straight up to disconnect. There are four connectors total. If your module has a separate main harness connector (usually gray or black multi-pin connector), disconnect it by pressing the release tab and pulling firmly.
   ⚠Do not pull on wires, only on connector bodies to avoid damaging terminals
3. 3

   Remove ignition coils
   Using an 8mm or 10mm socket (depending on model year), remove the single bolt securing each ignition coil. Gently twist and pull each coil straight up to remove from the spark plug well. Keep coils in order if reusing.
   ⚠If coils are difficult to remove, gently twist while pulling - do not pry or bend the coils
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
4. 4

   Locate and access ignition control module
   With coils removed, locate the ignition control module. On this platform, it is typically mounted on a bracket near the valve cover or integrated into the coil harness. If bracket-mounted, you will see a metal or plastic module approximately 3x4 inches with the main harness connector. Remove any wire routing clips or brackets securing the harness.
5. 5

   Remove module mounting hardware
   Remove the bolts or screws securing the ignition control module to its mounting bracket. Typically there are 2-3 bolts. Use the appropriate socket size (usually 10mm for mounting bolts). Carefully lift the module away from the mounting surface.
   ℹ️Some modules may have a ground wire attached - note location for reinstallation
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
6. 6

   Disconnect main module connector
   If not already disconnected, locate the main electrical connector on the ignition control module. Press the locking tab or slide the lock slider, then pull the connector straight off the module. Inspect connector terminals for corrosion or damage.
7. 7

   Remove old ignition control module
   Remove the ignition control module from the engine bay. Inspect the mounting bracket and harness for any damage or corrosion. Clean the mounting surface with electrical contact cleaner if present.
8. 8

   Prepare new ignition control module
   Remove the new ignition control module from packaging. Verify it matches the old unit exactly (connector configuration, mounting holes, part number). Apply a small amount of dielectric grease to the main connector terminals on the module side to prevent corrosion.
   ⚠Ensure replacement module part number matches exactly - wrong module can cause no-start or engine damage
9. 9

   Install new ignition control module
   Position the new module onto the mounting bracket, ensuring proper alignment. Install mounting bolts and tighten to specification. If there is a ground wire, ensure it is properly positioned under the bolt. Reconnect the main harness connector until it clicks into place.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
10. 10

    Reinstall ignition coils
    Inspect spark plug wells for any debris or oil. If oil is present, this indicates a valve cover gasket leak that should be addressed. Apply a thin coat of anti-seize compound to spark plug threads if plugs were removed. Install each ignition coil into its respective cylinder, pressing down firmly until fully seated. Install and torque coil bolts to specification.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)

    Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
11. 11

    Reconnect coil electrical connectors
    Reconnect each ignition coil electrical connector, pushing firmly until you hear and feel a positive click. Gently tug on each connector to verify it is locked in place. Secure any wire routing clips or brackets.
12. 12

    Reinstall engine cover and reconnect battery
    Reinstall the engine cover by aligning the clips and pressing down firmly until all clips engage. Reconnect the negative battery terminal and tighten securely. Clear any tool or parts from the engine bay.

Reassembly

1. Ensure all electrical connectors are fully seated and locked before starting engine
2. Double-check that no tools or parts were left in the engine bay
3. Verify engine cover is properly secured with all clips engaged

Verification

• Turn ignition to ON position (do not start) and verify check engine light performs normal bulb check then turns off
• Start the engine and verify it starts normally without extended cranking
• Engine should idle smoothly without misfires or rough running
• Rev engine gently to 2000-3000 RPM and verify smooth acceleration with no hesitation
• If check engine light illuminates, scan for diagnostic trouble codes using an OBD-II scanner
• Test drive vehicle to confirm normal operation under various load conditions
• After test drive, inspect for any loose connections or unusual sounds from the ignition system

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