Repair procedures: Removal

CAUTION:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:

Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

Disconnect the negative terminal from the battery.
Remove the engine cover.
Remove the air duct.

Fig 1: Identifying Air Duct
Courtesy of HYUNDAI MOTOR CO.
Remove the intake air hose and air cleaner assembly.
1. Disconnect the AFS connector(A).
2. Disconnect the breather hose(B) from air cleaner hose.
3. Disconnect the ECM connector. (Refer to COMPONENTS AND COMPONENTS LOCATION )
4. Remove the intake air hose(C) and air cleaner(D).
Fig 2: Identifying AFS Connector, Breather Hose, Intake Air Hose And Air Cleaner
Courtesy of HYUNDAI MOTOR CO.
Remove the RH front wheel.
Remove the under cover(A).

Fig 3: Identifying RH Front Wheel Under Cover
Courtesy of HYUNDAI MOTOR CO.
Remove the side cover(A).

Fig 4: Identifying RH Front Wheel Side Cover
Courtesy of HYUNDAI MOTOR CO.
Drain the engine coolant.
Remove the radiator cap to speed draining.
Remove the upper radiator hose(A).

Fig 5: Identifying Upper Radiator Hose
Courtesy of HYUNDAI MOTOR CO.
Drain the engine oil.
Remove the lower oil pan(A).
Insert the blade of SST(09215-3C000) between the upper oil pan and lower oil pan, and cut off applied sealer and removed lower oil pan.

Fig 6: Removing Lower Oil Pan
Courtesy of HYUNDAI MOTOR CO.
NOTE:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
- After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It be result in damage of the SST.
- Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
Install the jack to the upper oil pan.

Fig 7: Locating Upper Oil Pan
Courtesy of HYUNDAI MOTOR CO.
Just loosen the transaxle mounting bolts(A) without removing the transaxle mounting(B).

Fig 8: Identifying Transaxle Mounting With Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove the engine coolant reservoir tank (A).
Remove the engine mounting bracket (B).

Fig 9: Identifying Engine Coolant Reservoir Tank And Engine Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
Loosen the A/C pipe bracket mounting bolt (A).

Fig 10: Identifying A/C Pipe Bracket Mounting Bolt
Courtesy of HYUNDAI MOTOR CO.
Remove the no. 1 engine mounting (A) through the lower position of A/C pipe line.

Fig 11: Identifying No. 1 Engine Mounting
Courtesy of HYUNDAI MOTOR CO.
Remove the surge tank and engine wiring.
1. Disconnect the RH oxygen sensor connector(A).
  [3.3L]
  
  Fig 12: Identifying RH Oxygen Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
2. Disconnect the RH oxygen sensor connector(A) and VIS solenoid valve connector(B).
  
  Fig 13: Identifying RH Oxygen Sensor Connector And VIS Solenoid Valve Connector
  Courtesy of HYUNDAI MOTOR CO.
3. Disconnect the power steering oil pressure sensor connector(A).
  
  Fig 14: Identifying Power Steering Oil Pressure Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
4. Disconnect the RH injector connector(A) and the ignition coil connector(B).
  [3.3L]
  
  Fig 15: Identifying RH Injector Connector And Ignition Coil Connector (3.3L)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 16: Identifying RH Injector Connector And Ignition Coil Connector (3.8L)
  Courtesy of HYUNDAI MOTOR CO.
5. Disconnect the OCV connector(A) and knock sensor connector(B).
6. Disconnect the LH front oxygen sensor connector(C), alternator connector(D) and air compressor connector(E).
  
  Fig 17: Identifying OCV, Knock Sensor, LH Front Oxygen Sensor, Alternator And Air Compressor Connectors
  Courtesy of HYUNDAI MOTOR CO.
7. Disconnect the LH ignition coil connector(A), injector connector(B), condenser connector(C) and ground(D), and remove the wiring harness protector(E).
  
  Fig 18: Identifying LH Ignition Coil, Injector, Condenser Connectors, Wiring Harness Protector And Ground
  Courtesy of HYUNDAI MOTOR CO.
8. Disconnect the LH CMPS(A) and oil pressure switch connector(B).
  
  Fig 19: Identifying LH CMPS And Oil Pressure Switch Connector
  Courtesy of HYUNDAI MOTOR CO.
9. Disconnect the ETC connector(A) and the knock sensor connector(B).
  
  Fig 20: Identifying ETC Connector And Knock Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
10. Disconnect the PCSV connector(A), the MAP sensor connector(B) and the PCSV hose(C).
  [3.3L]
  
  Fig 21: Identifying PCSV Connector, MAP Sensor Connector And PCSV Hose (3.3L)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 22: Identifying PCSV Connector, MAP Sensor Connector And PCSV Hose (3.8L)
  Courtesy of HYUNDAI MOTOR CO.
11. Remove the ETC bracket(A).
12. Disconnect the water hoses(B) from the ETC.
13. Disconnect the PCV(C) hose.
  
  Fig 23: Identifying ETC Bracket, Water Hoses And PCV Hose
  Courtesy of HYUNDAI MOTOR CO.
14. Disconnect the brake vacuum hose.
15. Remove the surge tank stay(A).
  [3.3L]
  
  Fig 24: Identifying Surge Tank Stay (3.3L)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 25: Identifying Surge Tank Stay (3.8L)
  Courtesy of HYUNDAI MOTOR CO.
16. Remove the connector bracket(A) from the surge tank.
  
  Fig 26: Identifying Surge Tank Connector Bracket
  Courtesy of HYUNDAI MOTOR CO.
17. Remove the surge tank(A).
  [3.3L]
  
  Fig 27: Identifying Surge Tank (3.3L)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 28: Identifying Surge Tank (3.8L)
  Courtesy of HYUNDAI MOTOR CO.
  NOTE:
  - Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
Remove the cylinder head cover.
1. Remove the connector bracket (A) from the LH cylinder head cover.
  
  Fig 29: Identifying LH Cylinder Head Cover Connector Bracket
  Courtesy of HYUNDAI MOTOR CO.
2. Disconnect the RH ignition coil connector(A), the condenser connector (B) and remove the wiring bracket(C).
  
  Fig 30: Identifying RH Ignition Coil Connector, Condenser Connector And Wiring Bracket
  Courtesy of HYUNDAI MOTOR CO.
3. Remove the LH, RH ignition coil.
4. Remove the LH, RH cylinder head cover(A).
Fig 31: Identifying LH And RH Cylinder Head Cover
Courtesy of HYUNDAI MOTOR CO.
NOTE:
- Cover the upside of engine head with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
Set No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.
  NOTE: Do not rotate engine counterclockwise.
  
  Fig 32: Setting No. 1 Cylinder To TDC/Compression
  Courtesy of HYUNDAI MOTOR CO.
2. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration.
  If not, turn the crankshaft one revolution (360°).
  
  Fig 33: Identifying Mark On Camshaft Timing Sprockets
  Courtesy of HYUNDAI MOTOR CO.
  
  NOTE: Do not rotate engine counterclockwise.
Remove the drive belt(A).

Fig 34: Identifying Drive Belt
Courtesy of HYUNDAI MOTOR CO.
Remove the crankshaft damper pulley(A).

Fig 35: Identifying Crankshaft Damper Pulley
Courtesy of HYUNDAI MOTOR CO.
NOTE:
- Use the SST (flywheel stopper, 09231-3C300) to remove the crankshaft pulley bolt, after remove the starter.
Fig 36: Removing Crankshaft Pulley Using SST (Flywheel Stopper, 09231-3C300)
Courtesy of HYUNDAI MOTOR CO.
Lift up the engine assembly by using the jack.
Remove the power steering pump(A).

Fig 37: Identifying Power Steering Pump
Courtesy of HYUNDAI MOTOR CO.
Remove the air conditioner compressor(A).

Fig 38: Identifying Air Conditioner Compressor
Courtesy of HYUNDAI MOTOR CO.
Remove the alternator(A).

Fig 39: Identifying Alternator
Courtesy of HYUNDAI MOTOR CO.
Remove the drive belt idler(A).

Fig 40: Identifying Drive Belt Idler
Courtesy of HYUNDAI MOTOR CO.
Remove the drive belt auto tensioner(A).

Fig 41: Identifying Drive Belt Auto Tensioner With Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove water pump pulley(A).

Fig 42: Identifying Water Pump Pulley
Courtesy of HYUNDAI MOTOR CO.
Remove the timing chain cover(A).

Fig 43: Identifying Timing Chain Cover
Courtesy of HYUNDAI MOTOR CO.
CAUTION:
- Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
NOTE:
- Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
Fig 44: Identifying Timing Chain Identification Marks (1 Of 4)
Courtesy of HYUNDAI MOTOR CO.

Fig 45: Identifying Timing Chain Identification Marks (2 Of 4)
Courtesy of HYUNDAI MOTOR CO.

Fig 46: Identifying Timing Chain Identification Marks (3 Of 4)
Courtesy of HYUNDAI MOTOR CO.

Fig 47: Identifying Timing Chain Identification Marks (4 Of 4)
Courtesy of HYUNDAI MOTOR CO.
Install a set pin after compressing the RH timing chain tensioner.

Fig 48: Installing Set Pin
Courtesy of HYUNDAI MOTOR CO.
Remove the RH cam-to-cam guide(A).

Fig 49: Identifying RH Cam-To-Cam Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm(B).

Fig 50: Identifying RH Timing Chain Auto Tensioner And RH Timing Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR CO.
Remove the RH timing chain.
Remove the RH timing chain guide(A).

Fig 51: Identifying RH Timing Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pump chain cover(A).

Fig 52: Identifying Oil Pump Chain Cover
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pump chain tensioner assembly(A).

Fig 53: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pump chain guide(A).

Fig 54: Identifying Oil Pump Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pump chain sprocket(A) and oil pump chain(B).

Fig 55: Identifying Oil Pump Chain Sprocket And Oil Pump Chain
Courtesy of HYUNDAI MOTOR CO.
Remove the crankshaft sprocket(A) (O/P & RH camshaft drive).

Fig 56: Identifying Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.
Install a set pin after compressing the LH timing chain tensioner.

Fig 57: Installing Set Pin
Courtesy of HYUNDAI MOTOR CO.
Remove the LH cam-to-cam guide(A).

Fig 58: Identifying LH Cam-To-Cam Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm(B).

Fig 59: Identifying LH Timing Chain Auto Tensioner And LH Timing Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR CO.
Remove the LH timing chain.
Remove the LH timing chain guide(A).

Fig 60: Identifying LH Timing Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the crankshaft sprocket(A) (LH camshaft drive).

Fig 61: Identifying Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.
Remove the tensioner adapter assembly(A).

Fig 62: Identifying Tensioner Adapter Assembly
Courtesy of HYUNDAI MOTOR CO.