Remove and replace the serpentine belt on a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, including inspection of pulleys and tensioner.

Warnings

Tools required

Parts

• Serpentine belt × 1 — Use OEM specification for 2.5L I4 engine

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Open hood and secure with prop rod
4. Locate the belt routing diagram on the engine compartment label or take a detailed photo of the current belt path
5. Inspect engine bay for adequate working clearance from above

Procedure

1. 1

   Document belt routing
   Take a clear photo of the serpentine belt routing around all pulleys. The belt routes around the crankshaft pulley, idler pulley, alternator, water pump, and A/C compressor before wrapping around the tensioner. If the under-hood diagram is faded or missing, this photo is critical for correct reinstallation.
2. 2

   Locate the belt tensioner
   Identify the automatic belt tensioner on the driver's side of the engine. It is the spring-loaded pulley assembly with a 15mm hex bolt head in the center. Note the direction the tensioner arm moves when relieved.
3. 3

   Relieve belt tension
   Using a 15mm socket and breaker bar, rotate the tensioner pulley bolt clockwise to compress the tensioner spring. This will release tension on the belt. You will need to apply significant force and rotate approximately 45-90 degrees. An assistant can help remove the belt while you hold the tensioner compressed.
   ⚠Maintain firm control of the breaker bar as the tensioner will forcefully spring back when released
4. 4

   Remove serpentine belt
   While holding the tensioner in the relieved position, slide the belt off the tensioner pulley first, then carefully release the tensioner. Remove the belt from the remaining pulleys by working it off the alternator pulley last. Carefully lower the belt out from the engine compartment.
5. 5

   Inspect pulleys and tensioner
   With the belt removed, manually spin each pulley to check for rough bearings, excessive play, or noise. Inspect the tensioner pulley for smooth operation and check that the tensioner arm moves freely and returns to its extended position. Inspect all pulley surfaces for glazing, scoring, or damage. Check the idler pulley bolt for tightness.
   Torque spec

   Idler Pulley Bolt45 Nm (33 lb-ft)
6. 6

   Inspect old belt
   Examine the removed belt for cracking on the ribbed side, glazing, fraying, or chunks missing from the ribs. Check for oil or coolant contamination which indicates a leak that must be addressed. If the belt shows significant wear patterns on one edge, investigate pulley misalignment.
7. 7

   Install new serpentine belt
   Starting with the crankshaft pulley at the bottom, route the new belt around all pulleys according to your photo or the routing diagram, leaving the tensioner pulley for last. Ensure the belt ribs are properly seated in all pulley grooves. Verify the belt is routed correctly on both sides of each pulley with no twists.
8. 8

   Seat belt on tensioner
   Using the 15mm socket and breaker bar, rotate the tensioner clockwise to compress it again. While holding tension, carefully guide the belt onto the tensioner pulley, ensuring all ribs seat properly in the grooves. Slowly release the tensioner to apply proper tension to the belt.
   ⚠Control the tensioner release carefully to prevent the belt from jumping off adjacent pulleys
9. 9

   Verify belt installation
   Double-check that the belt is properly seated in all pulley grooves with no ribs riding on pulley edges. Compare the routing against your photo or diagram to confirm correct path. Visually confirm the belt is not twisted anywhere in its path. Manually rotate the crankshaft pulley one full revolution clockwise using a socket on the center bolt to verify smooth operation and that the belt stays seated on all pulleys.

Reassembly

1. No additional reassembly required for this procedure

Verification

• Start the engine and observe belt operation for 30 seconds, listening for squealing or chirping noises
• Verify the belt tracks properly on all pulleys without walking off to one side
• Check that the automatic tensioner maintains proper belt tension with no visible slack
• Turn off engine and perform a final visual inspection of belt seating on all pulleys
• Test all belt-driven accessories (alternator, A/C compressor) for proper function

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