This procedure covers the removal and replacement of the LED headlight module on a 2015 Kia Forte 1.8L I4, including electrical disconnection and proper alignment.

Warnings

Tools required

Parts

• LED headlight module assembly × 1 — Use OEM specification - specify driver or passenger side
• Headlight module connector seal (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key
3. Allow engine to cool completely if recently operated
4. Open hood and secure with prop rod
5. Gather all tools and new LED headlight module

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm wrench, loosen the negative battery terminal bolt and remove the cable from the battery post. Secure the cable away from the battery to prevent accidental reconnection. Wait at least 3 minutes to allow capacitors to discharge.
   Torque spec

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

   Access headlight assembly
   Identify the affected headlight (driver or passenger side). Remove the plastic engine cover if equipped by pulling upward on the clips. Locate the headlight module from behind the headlight housing in the engine bay. You may need to move aside wiring harnesses or coolant overflow tank for better access on the driver side.
3. 3

   Disconnect electrical connector
   Locate the main electrical connector on the back of the LED headlight module. Press the locking tab and pull the connector straight back to disconnect. Inspect the connector seal for damage or corrosion. If corrosion is present, clean with electrical contact cleaner and allow to dry completely.
4. 4

   Remove module dust cover
   Rotate the rubber dust cover counterclockwise approximately 1/4 turn and pull it off the back of the headlight housing. Set aside in a clean location. Inspect the dust cover for tears or deterioration and replace if damaged to prevent moisture intrusion.
5. 5

   Remove LED module mounting hardware
   Locate the module mounting bolts securing the LED headlight module to the housing (typically 2-3 bolts depending on configuration). Using an 8mm socket, remove the module mounting bolts completely. Keep bolts organized as they may vary in length.
   Torque spec

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

   Extract LED headlight module
   Carefully pull the LED module straight out from the headlight housing. Avoid twisting or angling the module to prevent damage to alignment tabs. If resistance is felt, check for any remaining fasteners or clips. Set the old module aside on a clean towel with the front facing up to protect the lens.
7. 7

   Inspect headlight housing
   With the module removed, inspect the headlight housing reflector and mounting surface for dirt, moisture, or damage. Wipe clean with a dry towel if needed. Check that the mounting surface is free of debris that could prevent proper seating of the new module. Verify alignment pins or tabs in the housing are intact.
8. 8

   Install new LED module
   Remove the new LED headlight module from its protective packaging, handling only by the exterior housing. Align the module with the headlight housing, ensuring any alignment tabs or pins engage properly. Insert the module straight into the housing until it seats fully against the mounting surface. The module should sit flush with no gaps.
9. 9

   Secure module mounting bolts
   Install the module mounting bolts by hand to start, ensuring they thread smoothly without cross-threading. Tighten the bolts in a cross pattern (if multiple bolts) to ensure even seating. Using a torque wrench and 8mm socket, torque all module mounting bolts to specification.
   Torque spec

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

    Reinstall dust cover
    Position the rubber dust cover over the back of the LED module, aligning any indexing features. Press the cover into place and rotate clockwise approximately 1/4 turn until it locks. Ensure the cover is fully seated all around to maintain weatherproof seal.
11. 11

    Reconnect electrical connector
    Align the electrical connector with the LED module connector terminal, ensuring the key features match. Push the connector straight onto the module until you hear or feel a positive click indicating the locking tab has engaged. Gently tug on the connector to verify it is locked in place.
12. 12

    Reconnect battery and test
    Reconnect the negative battery terminal cable to the battery post. Using a 10mm wrench and torque wrench, tighten the battery terminal bolt to specification. Turn the ignition to ON position (engine off) and verify the LED headlight module functions correctly in low beam, high beam, and DRL modes if equipped. Check for any error messages on the instrument cluster.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Reinstall any wiring harnesses or components moved during access
2. Reinstall plastic engine cover if removed, ensuring all clips are properly seated
3. Close hood and verify it latches securely

Verification

• Start the engine and verify no warning lights related to headlight system remain illuminated
• Test all headlight functions: low beam, high beam, turn signals, and DRL (if equipped) on the replaced side
• Compare light output and color temperature between both headlights to ensure they match
• Have headlight aim checked and adjusted by a professional or use headlight aiming equipment to verify proper beam pattern alignment
• Verify headlight housing is properly sealed with no visible gaps around the module

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