Complete state safety inspection procedure for a 2016-2024 Hyundai Tucson 2.5L I4 AWD, covering all required items per typical state inspection criteria including lights, brakes, suspension, tires, and emissions systems.

Warnings

Tools required

Preparation

1. Park vehicle on level ground with parking brake engaged
2. Place wheel chocks behind rear wheels
3. Start engine and allow to reach operating temperature (coolant temp gauge at normal)
4. Turn off engine and wait 2 minutes for systems to stabilize
5. Verify VIN matches registration documents

Procedure

1. 1

   Perform OBD-II emissions system scan
   Connect OBD-II scanner to diagnostic port located below steering column on driver's side. Turn ignition to ON position without starting engine. Read diagnostic trouble codes (DTCs) and verify all emissions monitors are in 'ready' status. Check for pending codes. Any active DTCs related to emissions components will result in inspection failure. Document monitor readiness status.
2. 2

   Inspect all exterior lighting
   Test all exterior lights with engine running: headlights (low and high beam), fog lights, turn signals (front/rear), hazard flashers, brake lights (all three including center high-mount), reverse lights, license plate lights, and side marker lights. Check for proper operation, correct color (amber for front turn signals, red for rear), and no cracks in lenses. All lights must illuminate properly for inspection pass.
3. 3

   Check horn and windshield wiper operation
   Test horn for proper operation and adequate volume. Operate windshield wipers through all speeds (intermittent, low, high) and verify washer fluid sprays adequately on windshield. Inspect wiper blades for tears, splits, or missing rubber - replace if streaking excessively. Check windshield for cracks longer than 6 inches in driver's field of view or star breaks larger than 1 inch.
4. 4

   Inspect tire condition and tread depth
   Using tread depth gauge, measure tread depth at minimum 3 points around each tire's circumference. Minimum legal tread depth is typically 2/32 inch (1.6mm) - record measurements. Inspect sidewalls for bulges, cuts, or weather checking. Check for uneven wear patterns indicating alignment or suspension issues. Verify all tires match size specifications on door jamb placard. Check tire pressure and adjust to specification (usually 35 PSI cold).
5. 5

   Test brake system operation
   With engine running, pump brake pedal 3-4 times and hold firm pressure. Pedal should remain firm without sinking - sinking indicates master cylinder or hydraulic leak. Test parking brake by engaging fully and attempting to move vehicle in drive - vehicle should not move. Check brake fluid level in reservoir under hood (should be between MIN and MAX marks). Inspect visible brake lines under hood for leaks, damage, or corrosion.
6. 6

   Raise vehicle and remove wheels
   Raise vehicle using floor jack at designated jacking points (reinforced pinch weld areas marked with triangular indicators). Support vehicle securely on jack stands at manufacturer-recommended support points. Remove all four wheels by loosening lug nuts in star pattern. Store wheels safely away from work area.
7. 7

   Inspect brake components at all four corners
   At each wheel, inspect brake rotors for minimum thickness, scoring, or heat cracks. Check brake pads for minimum thickness (must have at least 3mm pad material remaining). Inspect brake calipers for leaks, seized slide pins, or damage to rubber boots. Check brake hoses for cracks, bulging, or chafing. Verify no fluid leaks at caliper bleed screws or mounting points. For rear brakes, verify parking brake cables move freely without binding.
8. 8

   Inspect steering and suspension components
   Inspect all suspension components for excessive wear or damage: front lower control arm bushings (check for torn rubber or excessive movement), ball joints (check boots for tears and test for play), tie rod ends (check boots and test for looseness), sway bar links and bushings, strut/shock absorber mounts (check for leaking fluid). Check CV axle boots for tears or grease leakage. Inspect subframe and crossmember for damage or excessive rust. All rubber boots must be intact with no tears.
9. 9

   Inspect exhaust system and underbody
   Inspect entire exhaust system from manifold to tailpipe for leaks, excessive rust, or damage. Check all hangers and supports are intact. Verify catalytic converter is present and appears original (check for OEM stamps). Inspect heat shields for damage or missing fasteners that could cause rattling. Check fuel lines and fuel tank for leaks, damage, or excessive corrosion. Verify no fluid leaks from engine, transmission, transfer case, or differentials.
10. 10

    Check driveline components
    For this AWD model, inspect front differential for leaks at seals and mounting points. Check transfer case for fluid leaks. Inspect rear differential cover and pinion seal for leaks. Verify driveshaft U-joints or CV joints have no excessive play (grasp driveshaft and attempt to rotate - minimal movement is acceptable). Check all mounting hardware is present and tight.
11. 11

    Reinstall wheels and perform final torque
    Clean wheel mounting surfaces and hub faces of any rust or debris. Install wheels and thread lug nuts by hand. Lower vehicle until wheels contact ground but not fully weighted. Torque lug nuts to specification using star pattern to ensure even seating. Fully lower vehicle and perform final torque check in star pattern.
12. 12

    Perform interior safety inspection
    Inside vehicle, verify seat belts (all positions) retract properly, latch securely, and show no fraying or cuts in webbing. Test driver's seat adjustment controls operate smoothly. Check that all doors open from inside and outside. Verify driver door locks and unlocks from inside. Test emergency brake release mechanism. Inspect rearview and side mirrors for secure mounting and adequate reflection (no significant cracks).
13. 13

    Conduct road test
    Perform road test on level surface at speeds up to 45 mph if permitted. Verify steering operates smoothly without excessive play (less than 2 inches of free play at wheel rim). Test brakes during normal stop - vehicle should stop straight without pulling left or right. Listen for abnormal noises from suspension, drivetrain, or brakes. Verify transmission shifts smoothly through all gears. Confirm no warning lights remain illuminated on instrument cluster after startup sequence.

Reassembly

1. Ensure all wheels are torqued to specification in star pattern
2. Verify no tools or parts were left under vehicle or in engine bay
3. Reset trip odometer or record mileage for inspection documentation

Verification

• All warning lights extinguished after engine start (except normal temporary lights)
• No active diagnostic trouble codes present in OBD-II system
• All required lighting functions operate correctly
• Brake pedal remains firm under sustained pressure
• No fluid leaks visible under vehicle after inspection
• Tire tread depth meets or exceeds minimum legal requirement at all measurement points
• Vehicle tracks straight during road test with no pulls or unusual noises

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