This procedure covers removal and replacement of the ignition switch assembly on a 2016-2024 Hyundai Tucson with 2.5L I4 engine, including steering column disassembly and electrical connector work.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level surface and ensure transmission is in Park
2. Turn ignition to OFF position and remove key fob from vehicle interior
3. Disconnect negative battery terminal and wait minimum 3 minutes
4. Adjust steering wheel to lowest and fully extended position for access
5. Remove driver's side lower dashboard panel and knee bolster trim

Procedure

1. 1

   Remove lower steering column covers
   Locate and remove the cover screws securing the upper and lower steering column shrouds. There are typically 3-4 screws on the underside. Carefully separate the lower cover first, then remove the upper cover by sliding it forward off the column. Disconnect the hood release cable if attached to the lower cover.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Disconnect ignition switch wiring harness
   Locate the main ignition switch connector on the right side of the steering column. Press the locking tab and disconnect the primary electrical connector. If equipped with immobilizer, disconnect the secondary antenna ring connector. Note the routing of all wiring for reinstallation.
   ⚠Do not pull on wires - press connector release tab firmly to avoid damaging pins
3. 3

   Remove steering column mounting bracket (if necessary)
   Depending on switch access, you may need to lower the steering column slightly. Remove the two bracket bolts securing the column support bracket to the instrument panel support beam. Support the column weight before removing final bolt.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
4. 4

   Remove ignition switch mounting hardware
   Locate the switch mounting screws on the side of the steering column lock housing. These are typically tamper-resistant screws. Remove the 2-3 mounting screws securing the ignition switch to the lock cylinder housing. Keep all hardware organized for reinstallation.
   ℹ️Some ignition switches use break-away screws that must be drilled out - replacement will include new screws
   Torque spec

   Switch Mounting Screws5 Nm (4 lb-ft)
5. 5

   Extract ignition switch assembly
   Carefully slide the ignition switch assembly away from the lock cylinder housing. The switch should separate from the back of the lock cylinder. If resistance is felt, verify all mounting screws are removed and that no wiring is caught. Remove the switch completely from the vehicle.
   ⚠Do not force the switch - it should slide out with gentle pressure once all fasteners are removed
6. 6

   Inspect lock cylinder and housing
   With switch removed, inspect the lock cylinder housing for damage, wear, or debris. Check that the lock cylinder turns smoothly through all positions (LOCK, ACC, ON, START). Clean any debris from the housing using compressed air if available.
   ℹ️If lock cylinder is damaged or worn, this requires a separate replacement procedure with key reprogramming
7. 7

   Install new ignition switch
   Align the new ignition switch with the lock cylinder actuator slot. Ensure the switch is in the OFF position before installation. Slide the switch onto the lock cylinder housing until it seats fully against the mounting surface. Verify proper engagement by turning the key through all positions - switch should follow smoothly.
   ⚠Verify switch orientation matches original - incorrect installation will prevent key operation
8. 8

   Secure ignition switch mounting screws
   Install the switch mounting screws and tighten to specification using a torque wrench. Start all screws by hand first to ensure proper threading. Tighten in a cross pattern if multiple screws are present to ensure even seating.
   Torque spec

   Switch Mounting Screws5 Nm (4 lb-ft)
9. 9

   Reinstall steering column bracket
   If the steering column was lowered, raise it back to the original position. Install and tighten the bracket bolts to specification. Ensure column moves freely through full tilt and telescoping range without binding.
   Torque spec

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

    Reconnect electrical connectors
    Reconnect the primary ignition switch connector until it clicks into place. Reconnect the immobilizer antenna ring connector if equipped. Verify all connectors are fully seated and locking tabs engaged. Route wiring to match original configuration to prevent interference with steering column movement.
    ⚠Ensure no wiring is pinched between column covers or in tilt/telescope mechanism path
11. 11

    Reinstall steering column covers
    Position the upper steering column cover over the column and slide rearward into position. Install the lower cover and align all tabs. Install cover screws and tighten to specification. Reconnect hood release cable if applicable. Verify covers fit properly with no gaps.
    Torque spec

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

    Reinstall dashboard trim panels
    Reinstall the knee bolster and lower dashboard panel, ensuring all clips are fully engaged. Verify no rattles or loose trim pieces before proceeding to testing.

Reassembly

1. Reconnect negative battery terminal and tighten securely
2. Enter vehicle with key fob and allow smart key system to initialize (approximately 30 seconds)
3. Check that all dashboard warning lights perform normal self-test cycle

Verification

• Without starting engine, turn key through all positions: LOCK, ACC, ON - verify smooth operation in all positions
• Verify all accessory functions work in ACC position (radio, power windows)
• Verify all electrical systems activate in ON position (gauges, warning lights)
• Start engine and verify normal operation with no warning lights
• Test that key can be removed only in LOCK position and steering wheel locks properly
• Verify push-button start function works properly if equipped with smart key system
• Test that transmission shifter lock releases properly when brake is applied
• Confirm no airbag warning light or steering-related fault codes using diagnostic scanner if available

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