This procedure covers the removal and replacement of the engine cooling fan clutch on the 2016-2024 Hyundai Tucson with the 2.5L I4 gasoline engine and AWD.

Warnings

Tools required

Parts

• Engine cooling fan clutch × 1 — Use OEM specification
• Engine coolant × 1 — Hyundai/Kia Long Life Coolant (Green)

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 2 qt

Preparation

1. Ensure engine is completely cold to the touch (at least 2 hours after last operation)
2. Park vehicle on level ground and engage parking brake
3. Disconnect negative battery terminal to prevent accidental fan engagement
4. Place coolant drain pan under radiator drain plug
5. Remove engine cover by lifting upward on pull tabs if equipped

Procedure

1. 1

   Drain partial coolant
   Slowly open the radiator drain plug at the bottom of the radiator to drain approximately 2 quarts of coolant into the drain pan. This prevents coolant spillage when removing upper radiator components. Close drain plug finger-tight for now.
2. 2

   Remove upper radiator hose
   Locate the upper radiator hose connection at the radiator. Use pliers to compress and slide the hose clamp away from the connection point. Twist the hose gently to break the seal, then pull it off the radiator neck. Allow any remaining coolant to drain into the pan.
3. 3

   Remove radiator shroud fasteners
   Remove the upper radiator shroud mounting bolts (typically four 10mm bolts along the top edge of the shroud). Carefully lift the shroud upward slightly but do not fully remove yet, as it supports the fan assembly.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Access fan clutch nut
   With the shroud loosened, you now have access to the fan clutch center nut on the water pump shaft. The nut is a large 32mm or 36mm nut located at the center of the fan clutch assembly behind the fan blades.
5. 5

   Remove fan clutch assembly
   Using the appropriate size fan clutch wrench (32mm or 36mm), turn the fan clutch nut CLOCKWISE to loosen (left-hand threads). You may need to hold the water pump pulley steady using a strap wrench or have an assistant hold it. Once loose, unthread the clutch completely by hand and carefully lift the fan clutch and fan blade assembly straight up and out of the engine bay. Keep the assembly upright to prevent fluid leakage from the clutch.
   ⚠Remember: LEFT-HAND THREADS - turn clockwise to loosen, counterclockwise to tighten.
6. 6

   Inspect water pump shaft and threads
   With the fan clutch removed, inspect the water pump shaft threads for damage, wear, or coolant leakage. Check for any play in the water pump bearing by attempting to move the pulley up and down. Clean the threads with a clean rag if debris is present.
7. 7

   Install new fan clutch
   Position the new fan clutch onto the water pump shaft, ensuring proper alignment. Thread the clutch onto the shaft by hand, turning COUNTERCLOCKWISE (left-hand threads). Once hand-tight, use the fan clutch wrench to tighten the nut counterclockwise to the manufacturer's specification of 40-50 Nm (30-37 lb-ft). Do not overtighten as this can damage the water pump bearing.
   ⚠Do not drop the fan assembly or allow fan blades to strike the radiator during installation.
8. 8

   Reinstall radiator shroud
   Carefully lower the radiator shroud back into position, ensuring it properly seats on the lower mounting tabs. Install the upper shroud mounting bolts and tighten to specification using a torque wrench in a cross pattern.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Reconnect upper radiator hose
   Slide the upper radiator hose back onto the radiator neck, ensuring it is fully seated. Reposition the hose clamp over the connection point approximately 1/4 inch from the end of the neck and tighten to specification.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
10. 10

    Refill and bleed cooling system
    Tighten the radiator drain plug to specification. Fill the cooling system with Hyundai/Kia Long Life Coolant (Green) through the radiator cap opening until full. Start the engine with the radiator cap off and allow it to warm to operating temperature while monitoring coolant level. Add coolant as needed as air bubbles purge from the system. Once the thermostat opens and the upper radiator hose becomes hot, top off coolant and install the radiator cap. Check for leaks around all connections.
    Torque spec

    Coolant Drain Plug15 Nm (11 lb-ft)

Reassembly

1. Reinstall engine cover if equipped by pressing down firmly until clips engage
2. Reconnect negative battery terminal
3. Double-check all fasteners are properly torqued and all hose connections are secure
4. Verify no tools or parts remain in engine bay

Verification

• Start engine and verify cooling fan operates properly when engine reaches operating temperature
• Check for any coolant leaks around radiator hose connections and drain plug
• Listen for unusual noises from the fan clutch area during operation
• Verify fan clutch engages smoothly as engine warms up (fan noise should increase with temperature)
• Recheck coolant level after first drive cycle and top off if necessary
• Test drive vehicle and monitor temperature gauge to ensure normal operating temperature is maintained

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