This procedure covers removal and replacement of the harmonic balancer (crankshaft pulley) on the 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Harmonic balancer/crankshaft pulley × 1 — Use OEM specification
• Harmonic balancer bolt (if TTY) × 1 — Verify with service manual if replacement required
• Engine oil × 1 — Hyundai Genuine 0W-20

Fluids

• Hyundai Genuine 0W-20 — 5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure engine is completely cool
3. Disconnect negative battery terminal and isolate cable
4. Raise front of vehicle and support securely on jack stands
5. Remove front passenger-side wheel for better access
6. Remove engine splash shield/underbody panels to access crankshaft pulley area

Procedure

1. 1

   Remove drive belt
   Locate the drive belt tensioner on the front of the engine. Using a breaker bar or wrench on the tensioner bolt, rotate tensioner clockwise to release belt tension. Remove drive belt from all pulleys and note routing for reinstallation.
2. 2

   Remove engine cover and access components
   Remove plastic engine cover by pulling upward on mounting points. This may require removing cover bolts if equipped. Remove any air intake components or brackets that obstruct access to the crankshaft pulley area.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
3. 3

   Prevent crankshaft rotation
   Prevent the crankshaft from rotating during bolt removal. Options include: using a crankshaft holding tool inserted into the flywheel/flexplate access hole, using a strap wrench on the harmonic balancer, or having an assistant hold the crankshaft with a large socket and breaker bar on the balancer bolt while you break it loose from underneath.
   ⚠Do not attempt to prevent rotation by placing objects between starter teeth and flywheel as this can damage components.
4. 4

   Remove harmonic balancer bolt
   Using a breaker bar or impact wrench with appropriate socket (typically 19mm or 21mm), remove the harmonic balancer center bolt. This bolt is torqued to 133 lb-ft and may require significant force. Impact wrench is recommended. If the bolt is TTY (torque-to-yield), mark it for replacement and do not reuse.
   ⚠This bolt is very tight. Ensure crankshaft is properly restrained to prevent engine rotation.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
5. 5

   Remove harmonic balancer
   Install a proper harmonic balancer puller onto the balancer. Thread the puller center bolt into the crankshaft threads (ensure correct thread engagement). Tighten the puller center bolt while holding the puller arms steady until the balancer releases from the crankshaft. Do not pry or hammer on the balancer as this can damage the crankshaft or balancer.
   ⚠️Never use a jaw-type puller or hammer to remove the harmonic balancer. This can damage the crankshaft and cause catastrophic engine failure.
6. 6

   Inspect crankshaft nose and keyway
   Clean the crankshaft nose thoroughly with a wire brush and solvent. Inspect for any damage, scoring, or wear. Check that the crankshaft key (Woodruff key) is present, properly seated, and not damaged. Inspect the keyway in the crankshaft for damage or deformation.
   ⚠Any damage to the crankshaft nose, keyway, or key must be addressed before installing new balancer to prevent future failure.
7. 7

   Prepare new harmonic balancer
   Inspect the new harmonic balancer for any shipping damage. Verify the keyway slot in the balancer hub is clean and free of debris. Apply a thin coat of clean engine oil to the crankshaft nose and the inner bore of the harmonic balancer hub.
8. 8

   Install harmonic balancer
   Align the keyway in the harmonic balancer with the Woodruff key on the crankshaft. Carefully slide the balancer onto the crankshaft nose as far as it will go by hand. Use a harmonic balancer installation tool (threaded installer) or carefully tap using a large socket that contacts only the inner hub (not the outer ring) to fully seat the balancer onto the crankshaft.
   ⚠️Never strike the outer portion of the harmonic balancer. Only apply force to the inner hub to avoid separating the damper components.
9. 9

   Install and torque harmonic balancer bolt
   Install the harmonic balancer bolt (use new bolt if original was TTY). Hand-tighten the bolt first. Prevent crankshaft rotation using the same method as removal. Torque the bolt to 180 Nm (133 lb-ft) according to manufacturer specifications. If the service manual specifies additional torque-to-yield angle tightening, follow those instructions precisely.
   ⚠Verify with service manual whether additional angle tightening is required after reaching initial torque specification.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
10. 10

    Reinstall drive belt and components
    Route drive belt around all pulleys following the belt routing diagram (typically found on a decal under the hood or in the service manual). Rotate tensioner clockwise and slip belt onto final pulley. Release tensioner to apply proper tension. Reinstall any air intake components, brackets, and engine cover removed during disassembly.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
11. 11

    Reinstall underbody panels and wheel
    Reinstall engine splash shield and any underbody panels removed for access. Torque mounting bolts to specification. Reinstall passenger-side front wheel and torque lug nuts to manufacturer specification (typically 90-110 lb-ft for this vehicle).
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)

Reassembly

1. Double-check that all fasteners have been reinstalled and properly torqued
2. Verify drive belt is properly seated on all pulleys and tensioner is applying correct tension
3. Reconnect negative battery terminal
4. Check engine oil level and top off if necessary after performing repair

Verification

• Start engine and listen for any unusual noises from the front of the engine (knocking, rattling, or squealing)
• Observe harmonic balancer rotation through the lower engine area - it should spin smoothly without wobble or vibration
• Verify drive belt is tracking properly on all pulleys without slipping or misalignment
• Rev engine slightly (1500-2000 RPM) and confirm no vibration or abnormal noise
• Inspect for any oil leaks around the front crankshaft seal area after running engine for several minutes
• Test drive vehicle and confirm no unusual vibrations at idle or while driving

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