NHTSA ID Number: 10173547
Manufacturer Communication Number: 20-BE-004H
TSB/Document Date: 2020-04-07
Summary
Some 2019 & 2020 Elantra (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.
GROUP
NUMBER
BODY ELECTRICAL
20-BE-004H
DATE
Technical Service Bulletin
SUBJECT:
MARCH, 2020
MODEL(S)
ELANTRA (ADa)
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
Description: Some 2019 & 2020 Elantra (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…
Applicable Vehicles: Certain 2019-2020MY Elantra (ADa) produced from 9/10/2018 – 12/10/2019
equipped with halogen headlights.
Parts Information:
PART NAME
PART NUMBER
92101-F3500 (ADa,LH)
92102-F3500 (ADa,RH)
PART IMAGE
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT:
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
Warranty Information:
MODEL
OP. CODE
Elantra (ADa) 00DA10R0
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 the repair for this TSB, and the
affected part is still under warranty, please submit a separate 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.
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 #: 20-BE-004H
Page 2 of 11
SUBJECT:
4.
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
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 #: 20-BE-004H
Page 3 of 11
SUBJECT:
7.
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
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 #: 20-BE-004H
Page 4 of 11
SUBJECT:
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
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 #: 20-BE-004H
Page 5 of 11
SUBJECT:
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
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 #: 20-BE-004H
Page 6 of 11
SUBJECT:
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
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 #: 20-BE-004H
Page 7 of 11
SUBJECT:
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
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 #: 20-BE-004H
Page 8 of 11
SUBJECT:
4.
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
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 #: 20-BE-004H
Top of Beam Light
Page 9 of 11
SUBJECT:
7.
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
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 #: 20-BE-004H
Page 10 of 11
SUBJECT:
HEADLAMP REPLACEMENT AND AIMING ADJUSTMENT
For ease of adjustment for another Elantra
(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 #: 20-BE-004H
Page 11 of 11
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TSB/Document ID: 20-BE-004H
Replacement Service Bulletin Number:
MFR Communication Date: 2020-03-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EXTERIOR LIGHTING
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