Oh where do I start. 2003 Santa Fe, V6 Auto, FWD.

The engine has been making a loud ticking noise lately, starting right after an oil change it seemed. It actually sounded a lot like a stuck lifter, so I had an engine flush done, but this did not remedy the problem. Popping the hood one day it was particularly noisy, I noticed that it sounded like it was coming from the serpentine belt tensioner (or there abouts).

Anyway, tonight, *something* finally gave. All of a sudden I heard a squealing noise, then smelled burning rubber, and my battery light came on, and I lost my power steering. I figured that the tensioner finally gave out.

I turned off the vehicle to see what I could see. A bit of melted S-belt was it. I restarted it, and the belt was turning fine again, but while it was idling, I noticed that the crank pulley was shifting in and out now and then. When it moved inward, the S-belt shifted in as well, and started to rub on the timing cover, wearing a hole right through it! Have a look at the attached photo, showing the grove worn right through. :(

So I'm assuming that my tensioner was fine, and it was my crank pulley all a long. I'm figuring that 3 thing will need replacing:

1. Crank Pulley (the source of the problem)
2. Serpentine Belt (since it's probably half melted)
3. Timing Cover (can't see that water getting in there would be good)

Does this sound accurate?

This is my first post, so I thank all of you experts for chiming in with your 2 cents.

Cheers,

Ray

This post has been edited by wx_junkie: Jun 2 2008, 08:45 PM

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:00000732: wx!

How many miles on your 2003 Santa Fe? I have never heard of the crank pulley shifting in and out...the crank bolt is supposed to be torqued to about 160 lbs feet. And there are four 10mm positioning bolts around the crank bolt to hold the pulley while you torque it.

So either something is desperately wrong with the crank pulley, or you really mean the tensioner pulley. The crank pulley bolt literally has the highest torque specification for the whole Santa Fe.

Do replace the timing cover.
Do replace the serpentine belt.
Since you are probably over 60K miles, do replace the timing belt.
Do inspect the water pump and replace if questionable.
Do verify that you meant to say the tensioner pulley and arm as shown in the picture. Make sure that the arm is pulling back strongly, as you should never have enough slack for the S belt to wiggle back and forth. The spring in the tensioner arm may be worn.


Do go to hmaservice.com and register. While you are there, enter Santa Fe, 2003, 2.7 liter, Engine Mechanical, Timing Belt, Removal and Installation.

Byron

Thanks Byron for your reply.

There's 115,000 km on it (72,000 miles).

I meant the crankshaft pulley, and yes, there was something desperately wrong with it. After I removed the serpentine belt, the outer ring of the crank pulley just pulled right off. All that melted rubber that I thought was the belt was actually the crank pulley itself. This is why it was shifting in and out - it was really not attached anymore. Just the melted rubber in between gripping to keep it turning. All the other pulleys just kept in in line for the most part to prevent it from flying off.

So I've managed to get everything out except the crank pulley (what's left behind), as per my other thread I started. I'm not sure how to remove it. You say there are 4 10mm positioning bolts around the main bolt - I'm not sure I see this. Can you elaborate? See attached photo of the crank pulley, as maybe mine is different than what you're thinking. Anyway, I need to remove it so I can replace it, and the damaged lower timing cover as well.

I guess now I'm stuck as to why this happened to my crank pulley in the first place. As I said, the engines been making a loud ticking noise for a little bit, and it was coming from this area. All the other pulleys - water, alternator, tensioner, AC, idler, seem to rotate freely. Once I get it all back together with new parts, I'm hoping the ticking is gone. If it is still there or shows up again, I'll be sure to get it looked at ASAP while everything moves, to get a better diagnosis.

Thanks again.

This post has been edited by wx_junkie: Jun 3 2008, 11:10 AM

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Dear wx,

Your crank pulley problem belongs in the record books. It does look like you had serious rust corrosion issue. This pulley is a weighty chunk of steel so I am impressed that it wore out.

Picture:

The pulley on the 2004 Santa Fe has the four 10mm bolts surrounding the crank bolt; your 2003 does not have these [sorry] . You have a different assembly.

Do use an electric impact wrench to remove...these work great just use black anodized finish [impact rated] socket and extension.
Do get a new crank pulley from the dealer, as I am concerned that a crank pulley from another Canadian 2003 Santa Fe will be rusted as well.

Do torque to 130-138 lbs feet as shown.

Byron

the santa fe in common with many other makes has a rubber damper sandwich as part of the pulley, it is fitted to reduce vibration, it is not uncommon for thease to break up as yours has done but to be fair it's the first one l have heard off on the santa. l have changed several on other vehicles. as byron said your main problem is going to be getting the crankshaft bolt undone, it's very tight, try the electric wrench as byron suggested but you may need a compressed air wrench if it wont move

I having this same exact problem. I'm afraid to ask how much it would cost to get fixed...

changing the pulley is quite easy it's just the cost of the pulley (sorry can't help on the price of the part in the u.s)

I had a similar problem around 74,000 miles as the auto-tensioner bearing started to go bad and the whole tensioner had to be replaced. The dealer noticed it when the car was in for routine service. It was not an expensive repair; $130 parts and labor.

Edit: Nice to see my dealer was not lying. What happened to you is unfortunate but that is exactly what they said would happen to mine eventually if I had not fixed it.

This post has been edited by lovemysantafe: Jul 20 2008, 03:07 PM

just for an fyi, got mine fixed today, here's what it cost me. I think maybe the parts charges were a tad high, but maybe not. At least the parts and labor come with a 1 year warranty....

Santa Fe, 2.7L V6:
Serpentine Belt $45
Crankshaft Pulley/Damper $139
Labor: 1.7 hrs - $119

Next up, timing belt! Got a quote for $500... sound right?

the price sounds about right, pity you did not get the timing belt done at the same time as all that lot has got to come off again