Serpentine Belt Tensioner

This procedure covers the removal and replacement of the serpentine belt tensioner on the 2016-2024 Hyundai Tucson with the 2.5L I4 gasoline engine and AWD drivetrain.

Warnings

Tools required

Parts

• Serpentine belt tensioner assembly × 1 — Use OEM specification
• Serpentine belt (if worn or damaged) × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect the negative battery terminal and wait 3 minutes
3. Document the serpentine belt routing with a photo or diagram
4. Raise the front of the vehicle and secure on jack stands if additional access is needed from below
5. Remove the engine splash shield if equipped (10mm fasteners) for better access

Procedure

1. 1

   Remove upper engine cover if equipped
   Some models have a plastic engine cover secured with pull clips or 10mm bolts. Gently pull upward on the cover to release the grommets, or remove the fasteners and lift the cover away to access the serpentine belt system.
2. 2

   Locate the belt tensioner
   The automatic belt tensioner is located on the right side of the engine block, below the alternator. Identify the 14mm square or hexagonal drive point in the center of the tensioner arm that accepts a breaker bar or serpentine belt tool.
3. 3

   Release belt tension and remove serpentine belt
   Insert a 3/8-inch breaker bar or serpentine belt tool into the tensioner drive point. Rotate the tensioner clockwise (toward the front of the vehicle) to relieve tension on the belt. While holding tension released, slip the belt off the pulleys starting with the alternator or idler pulley. Slowly release the tensioner back to its resting position.
   ⚠Control the tensioner carefully as you release it. The spring tension is strong and can cause the arm to snap back forcefully.
4. 4

   Remove the serpentine belt
   Once tension is released, completely remove the serpentine belt from all pulleys and withdraw it from the engine bay. Inspect the belt for cracks, glazing, fraying, or missing ribs. Replace if any wear is evident.
5. 5

   Remove tensioner mounting bolt
   Using a 14mm socket with extension, remove the single bolt securing the tensioner to the engine block. The bolt threads directly into the block and may require moderate force to break free. Support the tensioner as you remove the bolt to prevent it from falling.
   Torque spec

   Belt Tensioner Bolt55 Nm (41 lb-ft)
6. 6

   Remove tensioner assembly
   Once the mounting bolt is removed, pull the tensioner assembly straight away from the engine block. There may be a locating dowel or alignment pin that keeps the tensioner positioned. Note the orientation of the tensioner for installation of the new unit.
7. 7

   Inspect tensioner pulley and mounting surface
   Check the mounting surface on the engine block for debris or damage. Spin the pulley on the old tensioner to verify it needed replacement (should show resistance, noise, or rough rotation). Clean the mounting surface with a clean rag.
8. 8

   Install new tensioner assembly
   Position the new tensioner onto the engine block, aligning any dowel pins or locating features. Ensure the tensioner arm is oriented correctly with the drive point accessible. Insert the mounting bolt by hand and thread it in several turns to ensure proper threading.
9. 9

   Torque tensioner mounting bolt
   Using a torque wrench and 14mm socket, tighten the tensioner mounting bolt to 55.0 Nm (41.0 lb-ft). This is a critical fastener that must be torqued to specification to prevent tensioner movement or failure.
   ⚠Do not over-torque the tensioner bolt as this can damage the threads in the aluminum engine block.
   Torque spec

   Belt Tensioner Bolt55 Nm (41 lb-ft)
10. 10

    Route new serpentine belt
    Following your photo or the routing diagram on the radiator shroud, route the new serpentine belt around all pulleys EXCEPT the final pulley (typically alternator or idler). Ensure the ribbed side of the belt contacts all grooved pulleys and the smooth side contacts any flat pulleys.
11. 11

    Install belt onto final pulley
    Insert your breaker bar into the tensioner and rotate it clockwise to create slack. Route the belt onto the final pulley, ensuring it is properly seated in all pulley grooves. Slowly release the tensioner to apply proper tension to the belt. Remove the breaker bar.
12. 12

    Verify belt installation
    Visually inspect that the belt is properly seated in all pulley grooves with no twists or misalignment. The belt should run true without shifting side-to-side. Compare the routing to your reference photo to confirm correct installation.

Reassembly

1. Reinstall the engine splash shield if removed, ensuring all fasteners are secure
2. Reinstall the upper engine cover if equipped, pressing firmly to seat all grommets
3. Reconnect the negative battery terminal and tighten securely
4. Lower the vehicle if raised

Verification

• Start the engine and listen for any squealing, chirping, or unusual noises from the belt area
• Observe the belt operation for 30 seconds to ensure it runs smoothly without slipping or vibration
• Rev the engine briefly to 2000-2500 RPM and verify the belt remains stable and quiet
• Turn off the engine and perform a final visual inspection to confirm the belt remains properly seated on all pulleys
• Check that the tensioner arm is positioned within its normal operating range and applying proper tension

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