This procedure covers the inspection, removal, and replacement of the serpentine (alternator) belt on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine and AWD drivetrain.

Warnings

Tools required

Parts

• Serpentine belt (alternator belt) × 1 — Use OEM specification - Hyundai part number varies by production date

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely (minimum 30 minutes after running)
3. Open hood and secure with prop rod
4. Locate the belt routing diagram on the radiator support or underside of hood (if present)

Procedure

1. 1

   Inspect current belt condition
   Visually inspect the serpentine belt for cracks, fraying, glazing, or missing ribs. Check belt tension by pressing on the longest belt span between pulleys - deflection should be approximately 5-10mm with moderate thumb pressure. Document belt routing by taking a photo or sketching the path around all pulleys including alternator, water pump, crankshaft, and tensioner.
2. 2

   Locate the belt tensioner
   The automatic belt tensioner is located on the upper right side of the engine (when viewed from the front). It has a 14mm hex bolt head in the center. The tensioner uses spring pressure to maintain belt tension automatically. Identify the direction the tensioner must be rotated to relieve tension - it will rotate clockwise to release tension on the belt.
3. 3

   Release belt tension
   Insert a 14mm socket on a 3/8" breaker bar or serpentine belt tool onto the tensioner center bolt. Rotate the tensioner clockwise firmly and smoothly to compress the tensioner spring and create slack in the belt. The tensioner will need to rotate approximately 45-60 degrees to provide sufficient slack.
   ⚠The tensioner is spring-loaded and will forcefully return to rest position when released. Maintain firm control of the tool.
4. 4

   Remove serpentine belt
   While holding the tensioner in the released position, slip the belt off the alternator pulley first, then release the tensioner slowly. Once tension is released, remove the belt from the remaining pulleys working from top to bottom. Remove the belt from the engine compartment and inspect all pulleys for damage, roughness, or bearing noise by spinning them by hand.
5. 5

   Inspect tensioner and pulleys
   Spin each pulley by hand to check for bearing roughness, noise, or excessive play. Inspect the tensioner arm for smooth operation and the tensioner pulley for wear grooves or damage. Check the alternator pulley for wobble or rough rotation. Replace any components showing wear or damage before installing the new belt.
6. 6

   Route new serpentine belt
   Begin routing the new belt by starting at the crankshaft pulley (lowest pulley), then work upward following your reference photo or the belt routing diagram. Route the belt around all pulleys EXCEPT the alternator pulley, ensuring the ribbed side of the belt contacts all grooved pulleys. Verify the belt is seated fully in each pulley groove before proceeding.
7. 7

   Install belt on alternator pulley
   Using the 14mm socket and breaker bar, rotate the tensioner clockwise again to relieve tension. While holding the tensioner, slip the belt onto the alternator pulley, ensuring it seats properly in the pulley grooves. Slowly release the tensioner, allowing it to apply proper tension to the belt. The tensioner will automatically set correct belt tension.
8. 8

   Verify belt installation
   Visually confirm the belt is properly seated in all pulley grooves with no misalignment. The belt should sit centered on each pulley. Check that the belt routing matches your reference photo or the routing diagram exactly. Ensure no part of the belt is twisted or contacting any sharp edges or components.
9. 9

   Test belt operation
   Manually rotate the crankshaft pulley clockwise two complete revolutions using a socket on the crankshaft bolt (do not start engine yet). Watch the belt tracking on all pulleys to ensure it remains centered and does not slip off. Listen for any unusual noises that might indicate misalignment or a defective component.

Reassembly

1. Double-check belt is seated properly on all pulleys before starting engine
2. Ensure no tools or materials are left in engine compartment
3. Close hood securely

Verification

• Start the engine and observe belt operation for the first 30 seconds, watching for proper tracking and listening for squealing or chirping noises
• With engine running at idle, verify the alternator is charging by checking that the battery warning light is off on the instrument cluster
• Turn on electrical loads (headlights, A/C, heated seats) and verify the alternator maintains charging without belt slipping or noise
• Allow engine to reach operating temperature and re-check belt for proper tracking and absence of noise
• After the first 100 miles of driving, re-inspect belt condition and seating on all pulleys

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