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 misconnecting.
To release the fuel system pressure before removing the engine assembly, start the engine with the fuel pump relay removed. And then turn off the ignition switch after engine stops.

Remove the engine cover (A).

Fig 1: Identifying Engine Cover
Courtesy of HYUNDAI MOTOR CO.
Disconnect the battery terminals (A). The negative terminal first.
Tightening torque

(+) terminal: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

(-) terminal: 4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
Remove the air cleaner assembly.
1. Remove the air duct (B).
2. Disconnect the breather hose (C).
3. Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).
  Tightening torque
  
  Hose clamp bolt:
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts:
  
  3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
  
  Fig 2: Identifying Air Duct
  Courtesy of HYUNDAI MOTOR CO.
  
  NOTE: Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
  
  Fig 3: Identifying Air Intake Hose
  Courtesy of HYUNDAI MOTOR CO.
Remove the battery (A) after removing the mounting bracket (B).
Tightening torque:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

Fig 4: Identifying Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
Disconnect the ECM connectors (A) and remove the ECM (B).
Tightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 5: Identifying ECM Connectors
Courtesy of HYUNDAI MOTOR CO.
Loosen the battery "+" cable bracket mounting bolt (A) and then remove the battery tray (B).
Tightening torque:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

Fig 6: Identifying Cable Bracket Mounting Bolt
Courtesy of HYUNDAI MOTOR CO.
Remove the under covers (A).
Tightening torque:

7.8 ~ 11.8 N.m (0.7 ~ 1.1 kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 7: Identifying Under Covers
Courtesy of HYUNDAI MOTOR CO.
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to COOLING SYSTEM )
Disconnect the radiator upper hose (A).

Fig 8: Identifying Radiator Upper Hose
Courtesy of HYUNDAI MOTOR CO.
Disconnect the radiator lower hose (A).

Fig 9: Identifying Radiator Lower Hose
Courtesy of HYUNDAI MOTOR CO.

NOTE: When installing radiator hoses, install as shown in illustrations.

Fig 10: Identifying Radiator Hoses
Courtesy of HYUNDAI MOTOR CO.
Recover the refrigerant and then remove the high pressure pipe (A) and the low pressure pipe (B). (Refer to AIR CONDITIONING SYSTEM .)

Fig 11: Identifying High Pressure Pipe
Courtesy of HYUNDAI MOTOR CO.
Remove the transaxle wire harness connectors, control cable and hoses from the transaxle.
Disconnect the brake booster vacuum hose (A) and the heater hoses (B).

Fig 12: Identifying Brake Booster Vacuum Hose
Courtesy of HYUNDAI MOTOR CO.

NOTE: When installing the heater hoses, install as shown in illustrations.

Fig 13: Identifying Heater Hoses
Courtesy of HYUNDAI MOTOR CO.
Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 14: Identifying Fuel Hose
Courtesy of HYUNDAI MOTOR CO.
Disconnect the "+" cable (A), the fuse box connector (B) and the EMS block (C) from the fuse/relay box and then remove the wiring protector after disconnecting the ground lines (D).

Fig 15: Identifying Cable And Connector
Courtesy of HYUNDAI MOTOR CO.
Disconnect the front oxygen sensor connector (A) and then remove it from the bracket. (ULEV only)

Fig 16: Identifying Front Oxygen Sensor Connector
Courtesy of HYUNDAI MOTOR CO.
Remove the front muffler (A).
Tightening torque:

39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

Fig 17: Identifying Front Muffler
Courtesy of HYUNDAI MOTOR CO.

CAUTION: Disconnect 2 oxygen sensor wiring clips (A) from under body before removing the front muffler.

Fig 18: Identifying Oxygen Sensor Wiring Clips
Courtesy of HYUNDAI MOTOR CO.
Remove the steering u-joint mounting bolt (A). (Refer to "STEERING GEAR BOX ")

Fig 19: Identifying Steering U-Joint Mounting Bolt
Courtesy of HYUNDAI MOTOR CO.
Remove the steering u-joint mounting bolt (A). (Refer to "STEERING GEAR BOX ")
Remove the lower arms (A). (Refer to "FRONT LOWER ARM ")

Fig 20: Identifying Lower Arms
Courtesy of HYUNDAI MOTOR CO.
Remove the stabilizer bar links (A). (Refer to "FRONT STABILIZER BAR ")

Fig 21: Identifying Stabilizer Bar Links
Courtesy of HYUNDAI MOTOR CO.
Remove the tie rod ends (A). (Refer to "STEERING GEAR BOX ")

Fig 22: Identifying Tie Rod Ends
Courtesy of HYUNDAI MOTOR CO.
Disconnect the drive shafts (A) from the axle hubs. (Refer to "FRONT DRIVESHAFT ")

Fig 23: Identifying Drive Shafts
Courtesy of HYUNDAI MOTOR CO.
Remove the roll rod bracket (A).
Tightening torque

Nut (B):

107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)

Bolt (C):

49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

Fig 24: Identifying Roll Rod Bracket
Courtesy of HYUNDAI MOTOR CO.
Remove the roll rod mounting support bracket (A).
Tightening torque:

44.1 ~ 39.2 N.m (4.5 ~ 6.0 kgf.m, 32.5 ~ 43.4 lb-ft)

Fig 25: Identifying Roll Rod Mounting Support Bracket
Courtesy of HYUNDAI MOTOR CO.
Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts.
Tightening torque

Sub frame mounting bolts & nuts:

156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)

Stay mounting bolts:

44.1 ~ 53.9 N.m (4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft)

Fig 26: Identifying Sub Frame
Courtesy of HYUNDAI MOTOR CO.
CAUTION:
- After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall down, so support them securely with floor jack.
- Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
Disconnect the ground line (A), and then remove the engine mounting support bracket (B).
Tightening torque

Ground line bolt (A):

10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)

Nut (C):

63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)

Bolt (D) and nuts (E):

49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

Fig 27: Identifying Ground Line
Courtesy of HYUNDAI MOTOR CO.
Disconnect the ground line (A), and then slowly loosen the transaxle mounting bolts (B).
Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Fig 28: Identifying Ground Line
Courtesy of HYUNDAI MOTOR CO.

Fig 29: Identifying Transaxle Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Lower the engine and transaxle assembly using a floor jack and then remove the engine and transaxle assembly by lifting vehicle.

Fig 30: Identifying Engine And Transaxle Assembly
Courtesy of HYUNDAI MOTOR CO.

CAUTION: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.