Hyundai Genuine Accessories

Vehicle Model Model Year HMA Part No. Vendor Part No.
Tucson 2010 ~ 2S061 ADU10 39025-998

Accessory Difficulty

Trailer Wiring Harness (B)

- Preparation - Disassembly - Accessory Installation - Function Check - Visual Check - Trouble Shooting

Note: Difficulty stated above reflects the minimum level of expertise required to install the accessory ( A ) Customer ( B ) Dealer Technician ( C ) Master Technician

Note: For ease of installation, install the trailer wiring harness before installing the trailer hitch.
Instructional Symbols / Definitions
Denotes warnings that may lead to serious physical injury or vehicle damage. Denotes quality processes to be checked prior to moving to the next step. Denotes safety equipment required to be used such as a mask, goggles, rubber gloves, and hearing protection.

Denotes cautions to be taken to avoid physical injury or electronic component damage.

Denotes specific tools that are necessary to complete the step. Mask Goggles

Denotes cautions to be taken to avoid vehicle and component damage.

Denotes instructional steps necessary to complete the process. Rubber Gloves Hearing Protection

Basic Required Hand Tools

Specialty Required Tools Vehicle Hoist

10mm
Ratchet

10mm Combo

Trim Panel Puller

Goggles

10mm
Phillips Screwdriver

10mm Socket

Wire Cutters

Notes to the Installer

Read the entire installation pamphlet prior to beginning the installation of the accessory. Ensure that the vehicle is properly protected in the area that the accessory is to be installed. To prevent vehicle damage, never place tools on top of painted surfaces, seats, dash pad, console or floor carpet / mat. Always wear appropriate safety gear to include gloves and eye protection when required. Safely use hoist to raise vehicle to allow easy installation of the hitch. Access to the underside of the vehicle is required.

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Hyundai Genuine Accessories

Kit Overview

No. 1 2 3 4 5 6 7 8

Qty.

1 28 1 1 1 13

Description No. Trailer Harness with Converter Module 9

Qty.

Description

No. 17 18 19 20 21 22 23 24

Qty.

Description

6 Cable Tie Alcohol Wipe Installation Manual Glove Box Card Foam Strips

10 11 12 13 14 15 16

Hardware Overview
A
28 Cable Tie

B
1 Alcohol Wipe

C
1 Installation Manual
15 AMP TOW HARNESS FUSE LOCATION.

NOTICE

D
39025-997 REV. A 02/08/2010

The 15 amp tow harness fuse is located under the hood, near the battery's positive (+) post. CAUTION: Only use a 15 amp replacement fuse, never use a higher rated fuse. Make sure the fuse cover is properly installed to prevent moisture intrusion.

WARNING
Overloading circuit can cause fires. DO NOT exceed: Max stop/turn light: 7.5 amps max current draw per side. Max tail lights: 7.5 amps max current draw. Read vehicle's owners manual for additional information.

Glove Box Card

E
13 Foam Strips

Hardware Kit Total 44

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Hyundai Genuine Accessories (Disassembly)

10mm Socket & Ratchet

N O T E

Record customers preset radio stations (if applicable). Using a 10mm socket, remove the Negative (-) battery cable and secure it away from the Negative (-) battery post. Failure to remove the Negative (-) battery cable prior to installation could damage or destroy electronic components.

Phillips Screwdriver
N O T E

Open rear hatch and locate the two screws on each of the tail light assemblies. Starting on the driver side, remove the two screws as shown above and carefully pull the tail light assembly straight back from the vehicle.
CAUTION: Do NOT scratch or damage tail light or vehicle body. Take caution not to break plastic clip on the sides holding tail light assemblies in place.

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Hyundai Genuine Accessories (Disassembly)

3
N O T E

Locate the taillight plugs. It will match the ends of the trailer wiring harness. Push down the locking tab and disconnect the driver side tail light plug. Lay the tail light assembly inside the vehicle. Do not allow tail light assembly to hang by the wiring harness. Repeat steps 2 and 3 to remove the tail light assembly from the passenger side of the vehicle.
CAUTION: Take care not to damage the locking tabs.

4
N O T E

Remove cargo floor covering from the vehicle to access the spare tire area. This will provide access to the (3) trim panel screws for the rear threshold.

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Hyundai Genuine Accessories (Disassembly)

Phillips Screwdriver
N O T E

Locate the (3) plastic Phillips head threshold screws in the inside of the threshold. Using a Phillips screwdriver, unscrew the center pin. Carefully pull the (3) plastic clips from the threshold and set aside. Grasp threshold on inside at outer screw locations and gently pull upward using a rocking motion to release four pressure clips on each side directly under the horizontal flat surface of the threshold cover and set aside. Carefully remove any pressure clips that remain seated in the rear threshold and place back onto plastic tabs on the base of the plastic threshold cover. CAUTION: Take care not to damage the clips holding the threshold.

8.50

N O T E

Phillips Screwdriver 6 Using a Phillips screwdriver, remove the (2) screws securing the trim panel on the driver side as shown above. On passenger side, remove jack assembly and repeat screw removal procedure from driver side.

N O T E

Trim Panel Puller 7 Using a trim panel puller, locate the (2) clips using the above dimensions. Pry the trim panel away from the vehicle. Grasping the edge of the trim panel, carefully pull back on the trim panel to access the vehicle wiring harness. Repeat procedure for passenger side. CAUTION: Take care not to damage the plastic clips holding the trim panels.
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Hyundai Genuine Accessories (Disassembly)

8
N O T E

On driver side tail light pocket, unseat grommet and push remaining harness and connector inside the vehicle. Repeat procedure for passenger side.

Hyundai Genuine Accessories (Accessory Installation)

10

N O T E

TRIM PANEL REMOVED FOR CLARITY On the driver side, use the alcohol wipe provided. Clean the flat surface on the floor behind the interior trim panel. Remove the protective tape from the back of the tow harness module and mount in the cleaned dry area as shown above, pressing firmly in place. Secure wire harness to floor with foam strip as shown above and in Steps 11 and 14 and repeat procedure for passenger side.

N O T E

On the driver side inside the vehicle, connect the tow hitch harness connector containing the yellow wire to the existing vehicle plug previously pushed through the grommet hole. Route the 4-flat trailer harness, power wire & remaining tail light connector through the hole and completely seat the new grommet. For ease of routing 4-flat harness through grommet hole, make sure dust cover remains open. Route the 4-flat harness and the power wire down to the underside of the vehicle between the vehicle bumper and body. Leave them for now, they will be installed later.

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Hyundai Genuine Accessories (Accessory Installation)

12

11

N O T E

Route the trailer harness connectors containing the green wire along the trim panel and out to the threshold area. Route across to the passenger side, along the threshold area. Route wire behind passenger side trim panel to the vehicle tail light harness. Secure harness run with (5) foam strips supplied in kit as shown above and press firmly to ensure adhesion.

N O T E

On passenger side inside the vehicle, connect the tail light harness containing the green wire to the existing vehicle tail light plug previously pushed through the grommet hole. Route the remaining plug through the hole and completely seat the new grommet.

CAUTION: Be careful not to pinch or cut any wires while routing wires. Secure wires in place where they cannot be pinched or cut.

Phillips Screwdriver

13

N O T E

Starting on the driver side, reconnect the tail light assembly to the mating plug at the tail light pocket area. Properly align and return the tail light assembly to its original position. Using a Phillips screwdriver, secure the assembly in place by reattaching the two screws removed in step 2. Repeat this procedure for the passenger side tail light assembly. CAUTION: Be careful not to pinch or cut any wires. Ensure that all alignment pins/tabs are correctly in place on tail light assemblies/body.

Wire Cutters

14

TRIM PANEL REMOVED FOR CLARITY

N O T E

From inside the vehicle starting on the driver side, route the harness downward towards the vehicle floor. Secure the harness at the upper and lower panel standoff mounts as shown above using (2) cable ties provided and trim excess cable tie ends with wire cutters.

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Hyundai Genuine Accessories (Accessory Installation)

Wire Cutters
N O T E

16

Wire Cutters
N O T E

15

Inside the vehicle on the passenger side, secure the harness at the lower panel standoff mount as shown above using (1) cable tie provided. Trim excess cable tie end with wire cutters.

From inside the vehicle starting on the driver side, take the loose wiring, connectors and cable tie to the harness as shown above using (1) cable tie provided to prevent rattling. Repeat procedure for passenger side. Trim excess cable tie end with wire cutters.

10mm Socket & Ratchet

18

N O T E

17
N O T E

On the passenger side, locate the white ground wire with the attached ring terminal. Route wire along the floor to the vehicle jack area. Secure wire to floor as shown above to prevent rattling using (2) foam strips provided and press firmly to ensure adhesion. If vehicle has optional audio amplifier, route wire adjacent to the side of the amplifier.

On the passenger side, locate the white ground wire with the attached ring terminal. Route wire up to the vehicle jack from underneath the trim panel as shown above. Make sure the white ground wire is routed in the channel under the trim panel as shown above to prevent the wire from being pinched. Locate the M6 bolt holding the vehicle jack bracket in place. Using a 10mm Socket & Ratchet, remove the M6 Bolt. Attach the ring terminal end of the ground wire to the M6 Bolt and re-attach bolt to bracket as shown above. Tighten securely to ensure a proper connection. CAUTION: Failure to properly tighten fastener will result in intermittent operation and or damage to the vehicles electrical system or trailer harness module.

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Hyundai Genuine Accessories (Accessory Installation)

Step 26

Step 25B

Wire Cutters
N O T E

20

Start routing wire forward where power wire exits the bottom of the vehicle on the driver side. Using (1) cable tie provided, attach the wire to the vehicle body in the existing hole near the rear bumper support. Trim excess cable tie end with wire cutters.

Step 25A

CAUTION: Avoid sharp edges, when routing wire.

Step 24

Step 23

Steps 20, 21,& 22

Wire Cutters

19

N O T E

GENERAL ROUTING OF POWER WIRE UNDER VEHICLE WITH REFERENCE TO STEP LOCATIONS ALONG DRIVER SIDE AS SHOWN ABOVE. Locate the Power Wire that was routed between the vehicle bumper and body in step 10. Begin routing the wire from the rear to the front of the vehicle to the battery using the supplied cable ties. When routing wire, follow the brake lines. Secure the wire harness to the brake lines using the cable ties provided and trim off excess cable tie ends with wire cutters. CAUTION: Avoid sharp edges, moving parts and heat sources when routing wire. Do not secure wires or cable ties to exhaust, springs, shocks or other moving parts.

Wire Cutters
N O T E

21

Route wire to the rear suspension/axle area, following existing brake line and across the frame to the rear sway bar making sure to avoid any moving parts as shown. Secure harness with (2) cable ties attached to brake line over the rear sway bar as shown above. Trim excess cable tie ends with wire cutters.

CAUTION: Avoid sharp edges, moving parts and heat sources when routing wire. Do not secure wires or cable ties to springs, shocks or other moving parts.

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Hyundai Genuine Accessories (Accessory Installation)

Wire Cutters
N O T E

22
N O T E

Wire Cutters

23

Route wire over the rear suspension/subframe, making sure to avoid any moving parts as shown. Secure wire to brake line using (1) cable tie provided as shown above. Trim excess cable tie end with wire cutters. CAUTION: Avoid sharp edges, moving parts and heat sources when routing wire. Do not secure wire or cable ties to exhaust, springs, shocks or other moving parts.

Continue routing wire adjacent to the fuel tank. Ensure the wire is routed over the fuel and vent hoses, secure wire using (2) cable ties provided as shown. Trim excess cable tie ends with wire cutters.
CAUTION: Avoid sharp edges, moving parts when routing wire. Do not

secure wires or cable ties to springs, shocks, sway bar or other moving parts.

25A

Wire Cutters, 10mm Socket & Ratchet, Trim Panel Puller

25B

Wire Cutters
N O T E

24

Route harness adjacent to the fuel tank and secure to the brake line using (2) cable ties provided as shown. Trim excess cable tie ends with wire cutters. Make sure to route the harness above the black emergency brake cable as shown.

CAUTION: Avoid sharp edges and moving parts when routing wire.

N O T E

Locate the (2) bolts and plastic nut holding the plastic protective shield to the vehicle. Using a 10mm Socket & Ratchet, remove the bolts. Using a trim panel puller, release the plastic nut/shield from the stud. Pull down on the protective shield and route the wire between the protective shield and vehicle floor. Route wire down the frame along the brake lines, routing up to the bulkhead area of the vehicle. Attach the wire to the brake line using the (3) cable ties provided, as shown above. Trim excess cable tie ends with wire cutters. Re-attach the protective shield using the (2) bolts and push the plastic nut over the stud at the front end of the shield. CAUTION: Avoid sharp edges when routing power wire.

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Hyundai Genuine Accessories (Accessory Installation)

Wire Cutters Wire Cutters

N O T E

27

26

Continue to route the power wire up between the engine and the bulkhead. Follow the brake lines up to the engine compartment area and secure wire to brake line as shown, using (3) cable ties provided. Trim excess cable tie ends with wire cutters. CAUTION: Avoid sharp edges, moving parts and heat sources when routing wire. Do not secure wires or cable ties to steering column or other moving parts.

N O T E

Continue to route the power wire up along brake line and attach to the brake line using (1) cable tie provided, in location shown above. Trim excess cable tie end with wire cutters.
CAUTION: Avoid sharp edges, moving parts and heat sources

when routing wire.

28A

10mm Socket & Ratchet

28B

N O T E

Open the battery terminal cover by pushing the tab and lift the lid to the left, as shown in Step 28A. Using a 10mm Socket, remove the nut closest to the battery stud. Route the power wire and ring terminal through the same hole that the battery cable is routed through on the terminal cover. With the 15 amp trailer fuse REMOVED, attach the ring terminal end of the Power Wire to the battery stud. Re-attach nut and tighten securely to ensure a proper connection, as shown in Step 28B. Replace battery terminal cover. CAUTION: Failure to properly tighten fastener will result in intermittent operation and or damage to the vehicles electrical system or trailer harness module.

Wire Cutters
N O T E

29

Place 15 amp trailer fuse back into the fuse holder. Secure remaining wire and fuse holder mounting bracket to the existing battery cable as shown above, using (2) cable ties provided. Trim excess cable tie ends with wire cutters.

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Hyundai Genuine Accessories (Re-Assembly)

10mm Socket & Ratchet

N O T E

30

Using a 10mm socket, re-attach the Negative (-) battery cable to the original position on the Negative (-) battery post and tighten securely.

Phillips Screwdriver

31

N O T E

On the driver and passenger side, return the interior trim panels to their original position, ensuring the mounting clips engage. Replace the two Phillips head screws on each side securing the trim panels removed during step 2. With the red/green wire routed down the threshold area, press the sill plate threshold cover firmly into its original position, ensuring the mounting tabs engage. Ensure the weather seal is not pinched under the threshold cover. With the threshold secured firmly in place, place (3) clips into holes and using a Phillips head screwdriver, screw the center of the clip back into place. Return the jack assembly and toolbag to its original position. Return the cargo floor cover to its original position.
CAUTION: Take care not to damage the clips holding the threshold and trim panels. Ensure that the threshold clips are engaged and the threshold is completely seated.

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Hyundai Genuine Accessories (Accessory Installation)

Wire Cutters

32
N O T E

11 33 Once the trailer hitch has been installed, locate the 4-flat harness bracket. Remove the dust cover from the 4-flat connector but leave loop around wire, as shown above. Carefully push the connector through the mounting bracket until the connector snaps into place. Loop dust cover around the bracket and re-attach cover onto the 4-flat harness.

N O T E

Locate the trailer wiring harness 4-flat connector routed between the vehicle bumper and body in step 10. Route the connector over the top of the bumper reinforcement and down the bumper Support bracket. Ensure the black spot tape is lined up with the support bracket as shown above to ensure correct length of the 4-flat to the mounting bracket. First, secure harness to the bumper support bracket closest to the black spot tape as shown above, with supplied cable tie. Secure the harness to the other support bracket as shown above to prevent rattling. The harness is attached to support bracket with (2) cable ties wrapped around the harness through the bumper holes as shown above. Trim off excess cable tie ends with wire cutters.

CAUTION: Be careful not to pinch or cut any wires.

Fuse Location Notice Card

11 34
N O T E

Place Fuse Location Notice Card in vehicle glove box.

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Hyundai Genuine Accessories (Function Check)

Items To Be Checked Use a 12V test light to check each signal function. a. Attach the ground lead to the male trailer connector pin. b. Verify the tail light circuit, right turn/brake and left turn/brake by activating each function on the vehicle individually while checking the appropriate terminal on the trailer connector. NOTE: The vehicle ignition must be in the ON position when testing the trailer wiring harness. Results of the Check Make sure test indicator shows all circuits working correctly. If the trailer wiring harness does not perform as noted, refer to the Trouble Shooting Tree on Page 16.

Right Turn/Stop Left Turn/Stop Tail Ground

Green Yellow Brown White

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Hyundai Genuine Accessories (Visual Check)

Items To Be Checked Trim Panels, Threshold Sill Plate, Floor Covering Results of the Check Make sure both trim panels and threshold plate are snapped into place making sure clips and rivets (three total) are fully seated and not damaged. Make sure all screws (four total) are re-inserted into the trim panels. Make sure floor covering is placed into its original position.

Tail Lights

Make sure both tail lights are installed correctly, ensure alignment pins are seated correctly. Make sure all screws (two each side) are placed back into position and tightened. Visually check that all wires are properly installed and attached to vehicle with provided cable ties. Ensure wires are not pinched, cut, near any heat sources or any moving parts. Make sure connections are fully seated with all locking tabs in place. Ensure there is no damage to locking tabs, connectors or moisture seals. Using wire cutters, make sure all excess plastic is cut from the cable ties. Make sure battery cable and all hardware is returned to its original position and all hardware is tight. Make sure 4-Flat dust cover has been properly routed and installed over the 4-Flat harness. Make sure the 15 Amp Trailer Fuse is inserted into the fuse holder and the sealed cap is re-installed on the fuse holder to prevent moisture intrusion.

All Wires

Tail Light Connection Points

Cable Ties

Battery Cables

4-Flat Harness Dust Cover

15 Amp Trailer Fuse

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Hyundai Genuine Accessories (Trouble Shooting Tree)

Using a Test Light, Check Left Turn, Right Turn, Brake Light and Tail Light Functions

Tools Required:
Test Light
All Outputs Functional With Same Intensity? No Check Harness & Trailer Fuse Beside Battery Replace Damaged Fuse Located in Fuse Holder Beside Battery Connect Trailer Yes Installation OK

Method:

1. Attach the test light ground connection to the male pin of the harnesss 4-Flat Connector. 2. Probe each of the female pins individually to confirm correct circuit operation.

No

Fuse OK? Yes Check Input Connector

Trailer Lighting Functions Reversed?

Yes

Check Trailer Connector for function Compatibility with Vehicle Connector Converter is Rated for 9 Amps and Has Automatic Shutdown Capability when Overload or Short Circuit Conditions are Present in Trailer. Repair Trailer or Remove Some of the Lamps in the Circuit. Converter will Re-set After a Short Period of Time Once the Short-Circuit Condition is Removed.

No

All Trailer Functions Operational? Yes End

No

Re-Seat Connector

No

Connection Good? Yes Check for 4-Flat Connector Damage

4-Flat OK? Yes Replace Converter

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