GROUP
CAMPAIGN
DATE

Technical Service Bulletin
SUBJECT:

DECEMBER, 2018

NUMBER
18-01-039
MODEL(S)
ELANTRA (AD/ADa)

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

 IMPORTANT

*** Dealer Stock and Retail Vehicles ***
Dealers must perform this Service Campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
When a vehicle arrives at the Service Department, access Hyundai Motor America's "Warranty Vehicle
Information" screen via WEBDCS to identify open Campaigns.
Description: Some 2019 Elantra (AD/ADa) vehicles equipped with halogen headlights may experience
intermittent operation of the high beam. This bulletin provides the service procedure to replace the left
and right headlamp assemblies and perform aiming adjustments.
NOTE:
ADa are vehicles with VIN starting with a number, for example 5NPD84LF…
AD are vehicles with VIN starting with a letter, for example KMHD84LF…

Applicable Vehicles: Certain 2019 Elantra (AD/ADa) equipped with halogen headlights.

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

SUBJECT:

Parts Information:
PART NUMBER
PART NAME

PREVIOUS

NEW

92101-F3500 (ADa,LH)
92102-F3500 (ADa,RH)
Headlamp
92101-F2540 (AD,LH)
92102-F2540 (AD,RH)

PART IMAGE

92101-F3500QQH (LH)
92102-F3500QQH (RH)

NOTE: Both the Elantra (AD) and Elantra (ADa) share the same NEW part number.

Warranty Information:
MODEL
OP. CODE
Elantra (AD)
(KMH…)

80C075R2

Elantra (ADa)
(5NP…)

80C075R3

OPERATION
HEADLAMP
REPLACEMENT AND
AIMING (BOTH SIDES)

OP. TIME CAUSAL PART NATURE CAUSE

0.9 M/H

92101-F3500

I11

ZZ3

NOTE 1: Submit Claim on Campaign Claim Entry Screen
NOTE 2: If a part is found in need of replacement while performing Service Campaign T3J and the
affected part is still under warranty, submit a separate warranty claim using the same Repair
Order. If the affected part is out of warranty, submit a Prior Approval Request for goodwill
consideration prior to performing the work.

TSB #: 18-01-039

Page 2 of 12

SUBJECT:

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

Service Procedure:
HEADLAMP REPLACEMENT
1.

Align the vehicle onto the lift. Do not lift the
vehicle up.

2.

If applicable, record the customer’s radio preset
stations for AM/FM/XM.

3.

Turn the wheel fully to the left or the right.

TSB #: 18-01-039

Page 3 of 12

SUBJECT:

4.

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

Open the hood and disconnect the negative (-)
cable on the battery.
Negative battery terminal tightening torque:
3.0~4.4 lb-ft (4.0~6.0 Nm, 0.4~0.6 kgf.m)

5.

Remove the six front bumper upper mounting
clips.

6.

Lift the vehicle to comfortable working height.

TSB #: 18-01-039

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SUBJECT:

7.

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

Remove one Phillips screw and three mounting
clips from front inner fender liner.
Perform the procedure to both the driver and
passenger side.

8.

Remove the 12 mounting clips and seven 10mm
bolts from the front under cover.
Tightening Torque for 10mm bolt:
2.9 ~ 4.3 lb-ft (3.9 ~ 5.9 Nm, 0.4 ~ 0.6 kgf.m)

9.

Remove the front under cover.

TSB #: 18-01-039

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SUBJECT:

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

10. From under the vehicle, disconnect the driver
and passenger turn signal light connectors.

11. Remove the front bumper.
Carefully pull the driver and passenger bumper
cover corners first, and then remove the front
bumper from the center.

12. Disconnect the driver and passenger headlamp
connectors.

TSB #: 18-01-039

Page 6 of 12

SUBJECT:

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

13. Remove the three headlamp mounting bolts.
Tightening Torque for 10mm bolt:
2.9 ~ 4.3 lb-ft (3.9 ~ 5.9 Nm, 0.4 ~ 0.6 kgf.m)
Tightening Torque for 12mm bolt:
5.1 ~ 8.0 lb-ft (6.9 ~ 10.8 Nm, 0.7 ~ 1.1 kgf.m)

14. Remove the headlamp by carefully pulling it
outward.

15. Remove the protective plastic film from the new
headlamps.

TSB #: 18-01-039

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SUBJECT:

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

16. Install the new headlamp and reinstall all
removed parts in reverse order.

NOTICE
When installing the driver and passenger
headlamps, align the three headlamp
tabs and hooks. Carefully push forward.
Ensure the locking tabs are fully inserted
into the hooks.

NOTICE
The driver side replacement headlamp
assembly will not include the extension
pigtail harness. The extension pigtail
harness is not needed.

Original Headlamp

Replacement Headlamp

TSB #: 18-01-039

Page 8 of 12

SUBJECT:

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)
HEADLAMP AIMING ADJUSTMENT

NOTICE
To perform the headlamp aiming check and adjustment, a distance of 25 feet is required
between the vehicle and wall or screen. Vehicle must also be on a flat surface.

1.

Park the vehicle on a flat surface in front of a
screen or wall.

2.

Check the front and rear tires pressure to
ensure it is inflated to the correct pressure
(36psi).
Adjust the tire pressure by inflating or deflating
as necessary.

3.

Measure 25 ft. from the wall and place two
pieces of masking tape or two marks
approximately 5.5 ft. apart from each other onto
the floor.

25 ft.

Approx. 5.5 ft.

TSB #: 18-01-039

Page 9 of 12

SUBJECT:

4.

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

Drive the vehicle toward the two marks/tapes on
the floor and align it to the center of the
headlight bulb.

The center point for the light bulb is the circle
imprinted on the headlights. It may be difficult to
see the imprinted circle, so viewing from
different angles is required.

5.

On the wall/screen, make two vertical marks of
approximately 6ft. apart and at a height of 26.2
inches.

Connect the two marks on the wall/screen using
masking tape or a marker.
26.2 inches
Approx. 6 ft.

6.

Turn the ignition switch to the ON position and
turn ON the headlamp.
Confirm if the top of the beam light is at the line
on the wall. If not, adjust the beam by following
the procedure described in the next step.

TSB #: 18-01-039

Top of Beam Light

Page 10 of 12

SUBJECT:

7.

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

Insert a Phillips screwdriver into the adjusting
hole and turn it clockwise or counterclockwise.
Turning the screwdriver clockwise will bring the
beam upward and counterclockwise will bring
the beam downward.

Insert Phillips Screwdriver

NOTICE
Perform the headlamp beam adjustment
with no one sitting in the driver or
passenger seat.

Example
Top of Beam Light

Headlight beam too low and requires adjustment
upward to the line on the wall which is 26.2 inches
high.

Headlight beam is now adjusted to the correct
height and specification.

TSB #: 18-01-039

Page 11 of 12

SUBJECT:

HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
(SERVICE CAMPAIGN T3J)

For ease of adjustment for another Elantra
(AD/ADa), make a mark or tape on the floor
using the alignment of the wheel center cap.
It is easier to align the wheel center cap than
center point of the headlamp light bulb.

Mark both sides of the vehicle as shown in the
picture to the right.

TSB #: 18-01-039

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