This procedure covers removal and replacement of the alternator on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including serpentine belt removal and electrical connections.

Warnings

Tools required

Parts

• Alternator × 1 — Use OEM specification for 2.5L AWD model
• Serpentine belt (if worn or damaged) × 1 — Use OEM specification

Preparation

1. Ensure vehicle is on level ground with parking brake engaged
2. Allow engine to cool completely if recently operated
3. Photograph or diagram serpentine belt routing from above engine bay
4. Disconnect negative battery terminal and secure cable away from battery post
5. Wait minimum 5 minutes after battery disconnection before proceeding

Procedure

1. 1

   Access alternator area
   Open hood and locate the alternator on the passenger side (right side) of the engine bay. The alternator is mounted to the front of the engine block below the intake manifold. Remove the engine cover if equipped by pulling upward on the cover clips.
2. 2

   Remove serpentine belt
   Locate the automatic belt tensioner on the front of the engine. Using a 14mm wrench or serpentine belt tool, rotate the tensioner clockwise to relieve belt tension. Slide the belt off the alternator pulley first, then carefully release tensioner pressure. Remove the belt from remaining pulleys and extract from engine bay. Inspect belt for cracks, glazing, or excessive wear.
3. 3

   Disconnect alternator electrical connections
   Locate the main B+ battery cable connection on the back of the alternator (red protective cap). Remove the protective cap and use a 10mm socket to remove the battery cable nut. Remove the cable and secure away from alternator. Disconnect the electrical connector from the alternator by pressing the release tab and pulling straight out.
   ⚠Ensure battery is disconnected before removing B+ cable to prevent arcing or short circuit
4. 4

   Remove upper alternator mounting bolt
   Locate the upper alternator mounting bolt on the top of the alternator bracket. Using a 14mm socket with extension, remove the upper alternator mounting bolt completely. Support the alternator with one hand to prevent it from falling.
   Torque spec

   Alternator Mounting Bolts50 Nm (37 lb-ft)
5. 5

   Remove lower alternator pivot bolt
   From underneath or through the wheel well area, locate the lower pivot bolt at the base of the alternator. Use a 14mm socket with 6-inch extension to remove the lower pivot bolt. The alternator may need to be tilted slightly to extract the bolt.
   Torque spec

   Alternator Pivot Bolt25 Nm (18 lb-ft)
6. 6

   Remove alternator from vehicle
   Carefully maneuver the alternator upward and toward the passenger side fender to clear the engine mounting bracket and other components. The alternator may need to be tilted at an angle to navigate past the intake manifold and radiator hoses. Extract the alternator from the engine bay.
7. 7

   Prepare new alternator
   Compare the new alternator to the old unit to verify correct replacement part, checking pulley size, mounting points, and electrical connection locations. Transfer any brackets or hardware if necessary. Clean the mounting surfaces on the engine block where the alternator mounts using a clean rag.
8. 8

   Install new alternator
   Carefully maneuver the new alternator into position, angling it past the intake manifold and other components. Align the alternator with the mounting bracket holes on the engine block. Hand-thread the lower pivot bolt first to hold the alternator in position, but do not tighten fully yet.
9. 9

   Install and torque mounting bolts
   Install the upper mounting bolt hand-tight. Once both bolts are started, torque the upper alternator mounting bolt to specification first, then torque the lower pivot bolt to specification. Ensure the alternator is properly seated against the mounting bracket before final torquing.
   Torque spec

   Alternator Mounting Bolts50 Nm (37 lb-ft)

   Alternator Pivot Bolt25 Nm (18 lb-ft)
10. 10

    Reconnect electrical connections
    Reconnect the electrical connector to the alternator until it clicks into place. Position the B+ battery cable terminal onto the alternator stud and install the nut. Torque the battery cable nut to specification. Reinstall the red protective cap over the B+ connection.
11. 11

    Install serpentine belt
    Route the serpentine belt around all pulleys according to the belt routing diagram or your documentation, leaving the alternator pulley for last. Rotate the belt tensioner clockwise to create slack, then slide the belt onto the alternator pulley. Carefully release the tensioner to apply proper belt tension. Verify the belt is properly seated in all pulley grooves.
12. 12

    Reconnect battery and test
    Reconnect the negative battery terminal and torque the terminal bolt to specification. Do not overtighten battery terminals. Start the engine and verify the alternator is charging properly by checking that the battery warning light extinguishes and battery voltage reads 13.5-14.5 volts with engine running. Listen for unusual noises from the alternator or belt area.
    ⚠Do not overtighten battery terminal bolts as this can damage the battery posts
    Torque spec

    Battery Terminal Bolts8 Nm (6 lb-ft)

Reassembly

1. Reinstall engine cover if removed by pressing down on mounting clips until seated
2. Verify all tools and parts have been removed from engine bay
3. Double-check that all electrical connections are secure and protective caps are installed

Verification

• Start engine and verify battery warning light extinguishes within 2-3 seconds
• Using a multimeter, confirm charging voltage at battery terminals reads 13.5-14.5 volts with engine running at idle
• Turn on electrical accessories (headlights, HVAC, radio) and verify voltage remains stable
• Listen for any unusual noises from alternator bearing or serpentine belt squealing
• Visually inspect serpentine belt alignment on all pulleys to ensure proper seating
• Test drive vehicle and verify no warning lights illuminate on instrument cluster

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