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How to Replace Tensioner Pulley on Hyundai Kia 2.4L Theta II Engine

DIY Cost: $ 30 - 40
Est. Time: 30 mins - 1 hour
Difficulty: Intermediate

Summary

Step-by-step instructions on how to replace the tensioner pulley ( drive belt tensioner) on Hyundai and Kia vehicles equpied with the 2.4L Theta II Engine. Pictures and videos are based on a 2019-2020 Kia Optima, but the same engine is used on several other Kia / Hyundai models.

What you will need

Procedure

  1. Park the vehicle and jack up the vehicle.Jacking up the Kia Optima 2016-2020.

     

  2. Place jack stands to support the vehicle.  Place wheel chocks behind the rear wheels to prevent vehicle from rolling back.Support the vehicle with jack stands.

     

  3. Remove the wheel well plastic cover on the driver's side to have easier access to the serpentine belt.
  4. Go under the vehicle on the driver's side and locate the tensioner pulley/idler pulleypulley.The tensioner pulley of the vehicle.

     

  5. Twist the 17mm bolt counterclockwise on the tensioner pulley to loosen the tension, use a 17mm wrench to twist the bolt, and pull the serpentine belt out.Removing the serpentine belt of the vehicle.Removing the serpentine belt of the vehicle.

     

  6. Remove the 2 Allen head bolts on the tensioner pulley and pull the whole unit of the tensioner pulley out from the top.The bolt on the other side of the tensioner pulley.Removing the tensioner pulley of the vehicle.Removing the tensioner pulley of the vehicle.

     

  7. Line up the pin on the new tensioner pulley to the vehicle and reinstall the 2 Allen head bolts.Installing the new tensioner pulley.

     

  8. Twist the tensioner pulley counterclockwise and reinstall the serpentine belt back to the vehicle.Reinstalling the serpentine belt.Reinstalling the new tensioner pulley.Reinstalling the serpentine belt of the vehicle.
  9. Make sure that all the ribs of the pulley are on the grooves of the serpentine belt.Checking the serpentine belt.
  10. Reinstall everything else you removed. Lower the vehicle to the ground and you are done replacing the tensioner pulley.

Tightening torque

  • 53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)

Notes

Engine

Applications

2.0L MPI (G4KD)

  • Hyundai Tucson/ix35 (LM) (2009–2015)
  • Hyundai Sonata (2007–2014)
  • Kia Forte (TD) (2008–2012)
  • Kia Optima/K5 (2008–2012)
  • Kia Sportage (SL) (2010–2013)

2.4L MPI (G4KE) 

  • Hyundai Azera (HG) (2013–2016)
  • Hyundai Grandeur (TG) (2008–2011)
  • Hyundai Santa Fe (2010–2020)
  • Hyundai Sonata (2007–2019)
  • Hyundai Tucson (2010–2020)
  • Kia Cadenza (2009–2019)
  • Kia Forte (TD) (2008–2012)
  • Kia Optima (2008–2019)
  • Kia Rondo (2008–2013)
  • Kia Sportage (2011–2021)
  • Kia Sorento (2009–2020)
How to Replace Tensioner Pulley on Hyundai Kia 2.4L Theta II Engine What you will need Car ramps or Jack Jack stands Wheel chocks Allen wrench 17mm wrench Tensioner pulley