This procedure covers the removal and replacement of the AC compressor on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including refrigerant recovery, component replacement, and system recharge.

Warnings

Tools required

Parts

• AC Compressor × 1 — Use OEM specification
• AC line O-rings × 4 — Use OEM specification
• Serpentine belt × 1 — Inspect and replace if worn
• R-134a refrigerant × 1 — Approximately 1.5 lbs
• PAG oil × 1 — ND-12 or equivalent

Preparation

1. Ensure engine is cold and vehicle is on level ground
2. Disconnect negative battery terminal and wait 3 minutes
3. Raise front of vehicle and secure on jack stands
4. Remove engine splash shield and passenger side wheel well liner for access
5. Verify AC system is fully recovered before beginning disassembly

Procedure

1. 1

   Recover refrigerant from AC system
   Connect AC recovery machine to low and high side service ports. Follow recovery machine instructions to fully evacuate refrigerant from the system. Record the amount of oil recovered for later replacement. Ensure recovery is complete before proceeding.
2. 2

   Remove serpentine belt
   Locate the serpentine belt tensioner on the right side of the engine. Use a serpentine belt tool or 14mm socket to rotate tensioner clockwise and release belt tension. Remove belt from all pulleys including the AC compressor pulley. Inspect belt for wear and replace if cracked or glazed.
3. 3

   Disconnect AC compressor electrical connector
   Locate the compressor clutch electrical connector on the front of the compressor. Press the release tab and disconnect the connector. Move wiring harness aside to prevent damage during compressor removal.
4. 4

   Disconnect AC refrigerant lines
   Locate the suction line (larger diameter) and discharge line (smaller diameter) connections at the rear of the compressor. Remove the bolt securing each line connection. Cap all open ports immediately with plugs to prevent moisture and debris entry. Discard old O-rings.
   ⚠Cap all open AC line ports within 15 minutes to prevent moisture contamination of the system.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
5. 5

   Remove compressor mounting bolts
   Support the compressor from below with one hand. Remove the four compressor mounting bolts securing the unit to the engine block bracket. The compressor weighs approximately 12 lbs. Carefully lower the compressor and remove from the engine bay.
6. 6

   Drain and measure compressor oil
   Drain oil from the old compressor into a measuring container by rotating it in different positions. Measure the total oil volume drained. The new compressor replacement will require the same amount plus any oil lost during recovery (typically 80-120ml total system capacity).
7. 7

   Prepare new compressor
   Remove shipping caps from new compressor ports. Drain the shipping oil from the new compressor. Add the correct amount of fresh ND-12 PAG oil based on measurements from old compressor plus recovered oil amount. Typical total is 100ml. Rotate compressor pulley by hand 10 times to distribute oil internally.
   ⚠Do not over-fill compressor with oil. Excess oil will reduce cooling capacity and can damage the system.
8. 8

   Install new compressor
   Position the new compressor onto the mounting bracket. Thread all four mounting bolts by hand first to ensure proper alignment. Tighten bolts in a cross pattern to specified torque.
9. 9

   Reconnect refrigerant lines
   Install new O-rings onto both AC line fittings. Lightly coat O-rings with a small amount of ND-12 PAG oil for lubrication. Connect suction and discharge lines to compressor. Install and tighten line bolts to specified torque. Do not over-tighten as this can damage O-rings.
   ⚠Always use new O-rings coated with PAG oil. Reused O-rings will likely leak.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Reconnect electrical connector
    Connect the compressor clutch electrical connector to the compressor. Ensure connector locks securely with an audible click. Verify connector is fully seated.
11. 11

    Reinstall serpentine belt
    Route new or inspected serpentine belt around all pulleys per the belt routing diagram on the radiator support. Use belt tool to rotate tensioner clockwise and slip belt onto the last pulley. Release tensioner slowly. Verify belt is properly seated in all pulley grooves.
12. 12

    Evacuate AC system
    Connect AC vacuum pump to service ports. Run vacuum pump for minimum 30 minutes to achieve 29+ inches Hg vacuum. Close service valves and monitor vacuum for 10 minutes. Vacuum should hold steady indicating no leaks. If vacuum drops, locate and repair leak before proceeding.
    ⚠System must hold vacuum for at least 10 minutes. Dropping vacuum indicates a leak that must be repaired.
13. 13

    Recharge AC system
    With engine off, connect manifold gauges to service ports. Add R-134a refrigerant through low-side port only. System capacity is approximately 1.3-1.5 lbs (consult underhood label for exact amount). Add refrigerant slowly to avoid overcharging. Monitor gauge pressures during charging.
14. 14

    Reinstall underbody panels
    Reinstall passenger side wheel well liner and engine splash shield. Ensure all clips and fasteners are properly secured. Reinstall wheel if removed. Lower vehicle from jack stands. Reconnect negative battery terminal.

Reassembly

1. Verify all AC line connections are tight and properly torqued to prevent leaks
2. Ensure serpentine belt is properly seated on all pulleys and tensioner is operating correctly
3. Confirm electrical connector to compressor clutch is fully engaged

Verification

• Start engine and turn AC to maximum cold with fan on high
• Verify compressor clutch engages and disengages with AC button
• Check that cold air is produced from vents within 2-3 minutes
• Monitor AC system pressures with gauges: low side should be 25-35 psi, high side 200-250 psi at idle with ambient temp 70-80°F
• Inspect all AC line connections for oil residue indicating leaks
• Check for unusual noises from compressor during operation
• Verify no refrigerant odor around engine compartment

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