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.
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 AMERICA
NOTE:
- To avoid damage, remove the engine cover on room temperature.
- To avoid damage of the engine cover, do not disengage both front and rear mounting point at the same time.
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:

3.9 ~ 5.9 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).
  Tightening torque:
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
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:
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Fig 2: Identifying Breather, Air Intake Hose And Air Cleaner Assembly
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
  - Install the air intake hose while the center of the mark of hose must be in line with the throttle body rib.
  Fig 3: Identifying Air Intake Hose Center Mark
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the battery (A) after removing the mounting bracket (B).
Tightening torque:

9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)

Fig 4: Identifying Battery & Mounting Bracket
Courtesy of HYUNDAI MOTOR AMERICA
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 AMERICA
Loosen the battery "+" cable bracket mounting bolt (A) and then remove the battery tray (B).
Tightening torque:

9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)

Fig 6: Identifying Battery Tray & Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the under cover (A).
Tightening torque:

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 7: Identifying Under Cover
Courtesy of HYUNDAI MOTOR AMERICA
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster.
(Refer to ENGINE COOLING SYSTEM - 2.0L article)
Disconnect the radiator upper hose (A).

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

Fig 9: Identifying Radiator Lower Hose
Courtesy of HYUNDAI MOTOR AMERICA
Recover the refrigerant and then remove the high pressure pipe and the low pressure pipe (A).
(Refer to AIR CONDITIONING SYSTEM article)

Fig 10: Identifying High & Low Pressure Pipes
Courtesy of HYUNDAI MOTOR AMERICA
Remove the transaxle wire harness connectors, control cable and hoses from the transaxle.
(Refer to AUTOMATIC TRANSAXLE SYSTEM - 2.0L article)
Disconnect the heater hoses (A).

Fig 11: Identifying Heater Hoses
Courtesy of HYUNDAI MOTOR AMERICA

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

Fig 12: Locating Heater Hoses Installation Directions
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the wiring connectors and harness clamps, and then remove the wiring and protectors from the cylinder head and the intake manifold.
1. The intake OCV (Oil control valve) connector (A)
  
  Fig 13: Identifying Intake Oil Control Valve Connector
  Courtesy of HYUNDAI MOTOR AMERICA
2. The exhaust OCV (Oil control valve) connector (A)
  
  Fig 14: Identifying Exhaust Oil Control Valve Connector
  Courtesy of HYUNDAI MOTOR AMERICA
3. The alternator connector (A)
  
  Fig 15: Identifying Alternator Connector
  Courtesy of HYUNDAI MOTOR AMERICA
4. The ignition coil connectors (A), fuel pump connector (B).
  
  Fig 16: Identifying Ignition Coil Connectors And Fuel Pump Connector
  Courtesy of HYUNDAI MOTOR AMERICA
5. The intake CMPS (Camshaft position sensor) connector (A)
6. The exhaust CMPS (Camshaft position sensor) connector (B)
  
  Fig 17: Identifying Camshaft Position Sensor Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
7. The injector connectors (A)
  
  Fig 18: Identifying Injector Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
8. The front and/or rear HO2S (Heated oxygen sensor connectors) (A)
  
  Fig 19: Identifying Heated Oxygen Sensor Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
9. The condenser connector (A)
  
  Fig 20: Identifying Condenser Connector
  Courtesy of HYUNDAI MOTOR AMERICA
10. The PCSV (Purge control solenoid valve) connector (A)
  
  Fig 21: Identifying Purge Control Solenoid Valve Connector
  Courtesy of HYUNDAI MOTOR AMERICA
11. The ECTS (Engine coolant temperature sensor) connector (A)
  
  Fig 22: Identifying Engine Coolant Temperature Sensor Connector
  Courtesy of HYUNDAI MOTOR AMERICA
12. The VIS (Variable Intake System) connector (A)
  
  Fig 23: Identifying Variable Intake System Connector
  Courtesy of HYUNDAI MOTOR AMERICA
13. The MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (A)
  
  Fig 24: Identifying Manifold Absolute Pressure Sensor And Intake Air Temperature Sensor Connector
  Courtesy of HYUNDAI MOTOR AMERICA
14. The ETC (Electronic throttle control) connector (A)
  
  Fig 25: Identifying Electronic Throttle Control Connector
  Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the "+" cable (A) and the front connector (B).

Fig 26: Identifying Front Connector & Cable
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 27: Identifying Fuel Hose And Purge Control Solenoid Valve Hose
Courtesy of HYUNDAI MOTOR AMERICA
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 28: Identifying Front Muffler
Courtesy of HYUNDAI MOTOR AMERICA
Remove the steering u-joint mounting bolt (A).
(Refer to STEERING GEAR BOX )

Fig 29: Identifying Steering U-Joint Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the front wheels.
(Refer to TIRES/WHEELS/WHEEL ALIGNMENT article)
Remove the lower arms (A).
(Refer to FRONT LOWER ARM )

Fig 30: Identifying Lower Arms
Courtesy of HYUNDAI MOTOR AMERICA
Remove the stabilizer bar links (A).
(Refer to FRONT STABILIZER BAR )

Fig 31: Identifying Stabilizer Bar Links
Courtesy of HYUNDAI MOTOR AMERICA
Remove the tie rod ends (A).
(Refer to STEERING GEAR BOX )

Fig 32: Identifying Tie Rod Ends
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the drive shafts (A) from the axle hubs.
(Refer to DRIVESHAFT ASSEMBLY )

Fig 33: Identifying Drive Shafts
Courtesy of HYUNDAI MOTOR AMERICA
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 34: Identifying Roll Rod Bracket, Nut & Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Remove the roll rod mounting support bracket (A).
Tightening torque:

49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

Fig 35: Identifying Roll Rod Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
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:

176.5 ~ 196.7 N.m (18.0 ~ 20.0 kgf.m, 130.2 ~ 144.7 lb-ft)

Fig 36: Supporting Sub Frame Using Floor Jack
Courtesy of HYUNDAI MOTOR AMERICA
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):

78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Bolt (D) and nuts (E):

78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Fig 37: Identifying Engine Mounting Support Bracket And Ground Line
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ground line (A).

Fig 38: Identifying Ground Line
Courtesy of HYUNDAI MOTOR AMERICA
Remove the service cover (A).

Fig 39: Identifying Service Cover
Courtesy of HYUNDAI MOTOR AMERICA
Remove the transaxle mounting bracket bolt (A).
Tightening torque:

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

Fig 40: Identifying Transaxle Mounting Bracket Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Lower the engine and transaxle assembly (A) using a floor jack and then remove the engine and transaxle assembly by lifting vehicle.

Fig 41: Removing Engine And Transaxle Assembly
Courtesy of HYUNDAI MOTOR AMERICA

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