This procedure replaces the AC compressor clutch coil on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, requiring removal of the serpentine belt and electrical connections to access the clutch assembly.

Warnings

Tools required

Parts

• AC compressor clutch coil × 1 — Use OEM specification
• Serpentine belt (if worn or damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake. Place wheel chocks behind rear wheels.
2. Turn off engine and allow to cool completely for at least 1 hour.
3. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge.
4. Raise front of vehicle and secure on jack stands at proper lift points.
5. Remove front passenger-side wheel for improved access to compressor area.
6. Remove plastic engine undercover if equipped (multiple 10mm bolts and push clips).
7. Take a reference photo of serpentine belt routing before removal.

Procedure

1. 1

   Remove serpentine belt
   Locate the serpentine belt tensioner on the upper right side of the engine. Using a 14mm wrench or serpentine belt tool, rotate the tensioner clockwise to release tension. Slide the belt off the AC compressor pulley first, then release tensioner and remove belt completely from all pulleys. Inspect belt for cracks, glazing, or excessive wear.
2. 2

   Disconnect AC clutch electrical connector
   Locate the electrical connector on the front of the AC compressor clutch coil. Press the locking tab and pull the connector straight away from the coil. Clean the connector with electrical contact cleaner if corrosion is present. If desired, use a multimeter to verify coil resistance at the connector (should be approximately 3-5 ohms if coil is functional).
3. 3

   Remove clutch coil retaining snap ring
   Using snap ring pliers, carefully remove the snap ring that secures the clutch coil to the compressor housing. The snap ring is located in a groove on the compressor front face, just inside the clutch pulley. Expand the snap ring and lift it out of the groove. Keep the snap ring in a safe location for reinstallation.
4. 4

   Extract the clutch coil assembly
   With the snap ring removed, carefully pull the clutch coil assembly straight off the compressor shaft. The coil should slide forward with moderate force. If the coil is stuck, gently rock it side to side while pulling. Do not pry against the compressor housing as this can damage the shaft seal. Note the orientation of any shims or spacers behind the coil for proper reinstallation.
5. 5

   Inspect compressor shaft and pulley
   With the coil removed, inspect the compressor shaft, clutch plate, and pulley bearing. Check for excessive play in the pulley bearing by attempting to move it radially. Inspect the clutch plate friction surface for wear, scoring, or oil contamination. Clean the compressor shaft and mounting surface with a wire brush and electrical contact cleaner to ensure proper seating of the new coil.
6. 6

   Install new clutch coil
   Position the new clutch coil assembly over the compressor shaft, ensuring any shims or spacers are correctly positioned in the same orientation as removed. Press the coil firmly onto the compressor housing until it seats completely against the mounting surface. Verify the coil sits flush and does not wobble. The electrical connector should face in the same direction as the original.
7. 7

   Install clutch coil snap ring
   Using snap ring pliers, install the snap ring into the groove on the compressor housing to secure the clutch coil. Ensure the snap ring is fully seated in the groove around its entire circumference. Tug gently on the coil to verify it is securely retained by the snap ring and cannot move forward.
8. 8

   Reconnect electrical connector
   Push the electrical connector firmly onto the clutch coil terminal until the locking tab clicks into place. Tug gently on the connector to verify it is locked. Ensure the connector wiring is routed away from moving components and the serpentine belt path.
9. 9

   Reinstall serpentine belt
   Route the serpentine belt around all pulleys according to the routing diagram (typically found on a decal in the engine bay or refer to your reference photo). Install the belt on the AC compressor pulley last. Rotate the belt tensioner clockwise to create slack, position the belt on the tensioner pulley, then slowly release the tensioner. Verify the belt is properly seated in all pulley grooves and not twisted.
10. 10

    Reinstall undercover and wheel
    Reinstall the plastic engine undercover if equipped, securing all bolts and clips. Reinstall the front passenger wheel and hand-tighten lug nuts. Lower the vehicle to the ground and torque lug nuts to 107-127 Nm (80-94 lb-ft) in a star pattern.

Reassembly

1. Reconnect the negative battery terminal.
2. Ensure all tools and parts have been removed from the engine bay.
3. Verify serpentine belt is properly routed and tensioned before starting engine.

Verification

• Start the engine and verify the serpentine belt runs smoothly without squealing or slipping.
• Turn on the AC system to maximum cold setting and observe the AC compressor clutch engagement. You should hear a distinct click and see the clutch plate rotate with the pulley.
• Verify cold air is produced from the vents within 1-2 minutes of AC activation.
• Check for any unusual noises from the AC compressor area during operation.
• Cycle the AC on and off several times to confirm reliable clutch engagement and disengagement.
• Monitor AC performance over the next few days to ensure consistent operation.

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