This procedure covers the removal and replacement of the LED headlight module assembly on the 2016-2024 Hyundai Tucson with 2.5L I4 engine, including proper electrical disconnection and aiming preparation.

Warnings

Tools required

Parts

• LED Headlight Module Assembly (Left or Right) × 1 — 92101-D3500 (LH) or 92102-D3500 (RH)
• Push-type retainer clips (if damaged) × 3 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off ignition and remove key/fob from vehicle
3. Allow engine and headlight assemblies to cool for at least 30 minutes if recently operated
4. Open hood and secure with prop rod
5. If preferred, mark headlight aim position on wall or garage door before removal for reference
6. Disconnect negative battery terminal and wait 3 minutes for system capacitors to discharge

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm socket, loosen the negative battery terminal bolt. Remove the cable from the battery post and secure it away from the terminal to prevent accidental reconnection during the procedure.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove front bumper cover fasteners (partial)
   Remove the upper radiator cover panel by releasing the push-type retainer clips. Remove the three bolts securing the upper portion of the front bumper cover near the headlight assembly using a 10mm socket. You do not need to fully remove the bumper, but creating access space is necessary.
3. 3

   Access headlight mounting area
   Locate and remove any plastic cover panels or dust shields in the engine bay directly behind the headlight assembly. These are typically secured with push clips or small fasteners. Set aside carefully for reinstallation.
4. 4

   Disconnect headlight electrical connectors
   Locate the main LED headlight module connector on the back of the headlight assembly. Press the release tab and carefully pull the connector straight back to disconnect. If equipped with adaptive headlights, disconnect the additional leveling motor connector. Touch a grounded metal surface before handling connectors to discharge static electricity.
   ⚠Do not pull on wires. Always grasp the connector body itself when disconnecting.
5. 5

   Remove headlight mounting bolts
   Locate the three headlight module mounting bolts. There are typically two bolts accessible from the top and one from the side or bottom of the assembly. Using an 8mm socket, remove all three mounting bolts completely. Keep bolts organized for reinstallation.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
6. 6

   Extract headlight assembly
   Carefully pull the headlight assembly forward and outward from the vehicle. The assembly may be held by alignment pins or clips, so apply steady pressure while working it free. Avoid forcing; check for any remaining fasteners or clips if resistance is encountered. Once free, remove the assembly completely from the vehicle.
7. 7

   Inspect mounting points and connectors
   Examine the headlight mounting bracket area for any damage, corrosion, or debris. Check the electrical connector on the vehicle harness for corrosion or damaged pins. Clean the mounting surface and connector with electrical contact cleaner if needed. Verify the new headlight module matches the original in connector configuration and mounting points.
8. 8

   Install new LED headlight module
   Position the new headlight assembly into the mounting location, aligning the positioning pins and tabs with the vehicle body. Ensure the assembly seats fully and evenly before installing fasteners. The headlight should sit flush with the surrounding bodywork.
   ⚠Avoid touching LED arrays or reflective surfaces. Handle assembly by the housing only.
9. 9

   Install mounting bolts
   Install all three headlight module mounting bolts finger-tight initially to ensure proper alignment. Once all bolts are started, torque each bolt to specification in a cross pattern using an 8mm socket and torque wrench. This ensures even seating of the assembly.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
10. 10

    Reconnect electrical connectors
    Touch a grounded metal surface to discharge any static electricity. Connect the main LED headlight module connector, ensuring it clicks fully into place. If equipped, reconnect the adaptive headlight leveling motor connector. Verify each connector is fully seated and the locking tab is engaged.
11. 11

    Reinstall access covers and bumper fasteners
    Reinstall any dust shields or plastic covers removed from behind the headlight assembly. Reinstall the upper bumper cover bolts and push-type retainer clips. Ensure all clips are fully seated and the bumper cover aligns properly with the new headlight assembly.
12. 12

    Reconnect battery and test operation
    Reconnect the negative battery terminal and torque the terminal bolt to specification using a 10mm socket. Turn the ignition to ON (engine off) and test all headlight functions: low beam, high beam, daytime running lights (if equipped), and turn signals. Verify the LED module illuminates properly without flickering or error messages on the instrument cluster.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all push-type retainer clips are fully installed in bumper cover
3. Check that headlight assembly sits flush with surrounding body panels with no gaps
4. Confirm all mounting bolts are torqued to specification

Verification

• Start the engine and verify no warning lights appear on the instrument cluster related to headlight malfunction
• Test all headlight functions: low beam, high beam, turn signals, and daytime running lights
• Visually inspect the LED pattern for proper illumination with no dark spots or flickering
• Check headlight aim using a wall or target at 25 feet distance; the beam pattern should be similar to the opposite side
• Schedule professional headlight aiming if beam pattern appears significantly different from pre-repair condition
• Verify the headlight assembly is securely mounted with no movement or vibration

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