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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.

Disconnect the terminals (A) from battery and remove the battery.

Fig 1: Locating Battery Terminals
Courtesy of HYUNDAI MOTOR CO.
Remove the engine cover.
Remove the under cover (A).

Fig 2: Locating Under Cover
Courtesy of HYUNDAI MOTOR CO.
Drain the engine coolant.
Remove the radiator cap to speed draining.
Remove the intake air hose and air cleaner assembly.
1. Disconnect the breather hose (B) from intake air hose (D).
2. Remove the intake air hose (D) and air cleaner upper cover (C).
  
  Fig 3: Locating Intake Air Hose And Air Cleaner Upper Cover
  Courtesy of HYUNDAI MOTOR CO.
3. Disconnect the ECM connector (A) and ECM connector (B) (A/T only).
4. Remove the air cleaner element and air cleaner lower cover (C).
  
  Fig 4: Locating Air Cleaner Element And Air Cleaner Lower Cover
  Courtesy of HYUNDAI MOTOR CO.
Remove the battery tray (A).

Fig 5: Locating Battery Tray
Courtesy of HYUNDAI MOTOR CO.
Disconnect the upper radiator hose (A) and lower radiator hose (B).
Disconnect the ATF oil cooler hoses (C).

Fig 6: Locating ATF Oil Cooler Hoses
Courtesy of HYUNDAI MOTOR CO.
Disconnect the heater hoses (A).
Disconnect the fuel hose (B).

Fig 7: Locating Heater Hoses And Fuel Hose
Courtesy of HYUNDAI MOTOR CO.
Remove the accelerator cable (A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.
Disconnect the TPS (Throttle Position Sensor) connector (B) and the MAP sensor connector (C).

Fig 8: Locating Throttle Position Sensor Connector And MAP Sensor Connector
Courtesy of HYUNDAI MOTOR CO.
Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
1. Disconnect the rear oxygen sensor connector (A).
2. Disconnect the air conditioner compressor switch connector (B).
3. Disconnect the knock sensor connector (C).
4. Disconnect the injector connectors (No. 3, 4) (D).
5. Disconnect the injector connectors (No. 1, 2) (E)
  
  Fig 9: Locating Knock Sensor Connector And Injector Connectors (No. 1, 2)
  Courtesy of HYUNDAI MOTOR CO.
6. Remove the wire harness bracket (A).
7. Disconnect the ISA (Idle Speed Actuator) connector (B).
  
  Fig 10: Locating Idle Speed Actuator Connector
  Courtesy of HYUNDAI MOTOR CO.
8. Disconnect the front oxygen sensor connector (A).
9. Disconnect the CKP (Crankshaft Position Sensor) connector (B).
10. Disconnect the OCV (Oil Control Valve) connector (C).
  
  Fig 11: Locating Oil Control Valve Connector
  Courtesy of HYUNDAI MOTOR CO.
11. Disconnect the ignition coil connector (A).
12. Disconnect the ignition coil condenser connector (B).
13. Disconnect the CMP (Camshaft Position Sensor) connector (C).
14. Disconnect the ground cable (D).
15. Remove the wire harness bracket (E).
  
  Fig 12: Locating Wire Harness Bracket
  Courtesy of HYUNDAI MOTOR CO.
16. Remove the ground cable (A) between engine mounting and vehicle body.
  
  Fig 13: Locating Ground Cable Between Engine Mounting And Vehicle Body
  Courtesy of HYUNDAI MOTOR CO.
17. Remove the ground cable (A) between transaxle housing and vehicle body.
  
  Fig 14: Locating Ground Cable Between Transaxle Housing And Vehicle Body
  Courtesy of HYUNDAI MOTOR CO.
Remove the transaxle wire harness connectors and control cable from transaxle (A/T).
1. Disconnect the transaxle range switch connector (A).
2. Disconnect the solenoid valve connector (B).
3. Disconnect the ATF oil temperature sensor connector (C).
  
  Fig 15: Locating ATF Oil Temperature Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
4. Disconnect the vehicle speed sensor connector (A).
5. Disconnect the band server switch connector (B).
6. Disconnect the pulse generator (A) connector (C).
7. Disconnect the pulse generator (B) connector (D).
  
  Fig 16: Locating Pulse Generator And Connector
  Courtesy of HYUNDAI MOTOR CO.
8. Remove the control cable nut (A) from transaxle range switch.
9. Remove the control cable (B).
  
  Fig 17: Locating Control Cable Nut And Control Cable
  Courtesy of HYUNDAI MOTOR CO.
Remove the transaxle wire harness connectors and control cable from transaxle (M/T).
1. Disconnect the vehicle speed sensor connector (A).
2. Disconnect the neutral switch connector (B).
3. Disconnect the back-up lamp switch connector (C).
  
  Fig 18: Locating Vehicle Speed Sensor Connector And Neutral Switch Connector
  Courtesy of HYUNDAI MOTOR CO.
4. Remove the control cable (A).
  
  Fig 19: Locating Control Cable
  Courtesy of HYUNDAI MOTOR CO.
Move the disconnected wire harnesses to the fuse box side so as to prevent interfering with other parts.
Disconnect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.
Remove the brake booster vacuum hose (B).

Fig 20: Locating Brake Booster Vacuum Hose
Courtesy of HYUNDAI MOTOR CO.
Remove the power steering oil hose (A) and drain the power steering oil.

Fig 21: Locating Power Steering Oil Hose
Courtesy of HYUNDAI MOTOR CO.
Remove the power steering return hose (A).

Fig 22: Locating Power Steering Return Hose
Courtesy of HYUNDAI MOTOR CO.
Recovering refrigerant and remove the high & low pressure pipe. (Refer to AIR CONDITIONING SYSTEM ).
Remove the nuts (B, D), bolt (C) and engine mounting support bracket (A).
Tightening torque:

Nut (B):

68.6 ~ 93.2 N.m (7.0~ 9.5 kgf.m, 50.6 ~ 68.7 lb-ft)

Bolt (C), Nut (D):

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

Fig 23: Locating Nuts, Bolt And Engine Mounting Support Bracket
Courtesy of HYUNDAI MOTOR CO.
Remove the transaxle mounting bracket (A).
Tightening torque:

Bolt, Nut (B):

68.6 ~ 93.2 N.m (7.0~ 9.5 kgf.m, 50.6 ~ 68.7 lb-ft)

Fig 24: Locating Transaxle Mounting Bracket - A/T
Courtesy of HYUNDAI MOTOR CO.

* A/T : Remove the wire harness protector (B) on the transaxle mounting support bracket.

Fig 25: Locating Transaxle Mounting Bracket - M/T
Courtesy of HYUNDAI MOTOR CO.

* M/T : Remove the clutch release cylinder oil hose (B) on the transaxle mounting support bracket.
Disconnect the alternator connector (A) and "B" terminal (B).

Fig 26: Locating Alternator Connector And B Terminal
Courtesy of HYUNDAI MOTOR CO.
Remove the front tires.
Remove the ABS wheel speed sensor (A).

Fig 27: Locating ABS Wheel Speed Sensor
Courtesy of HYUNDAI MOTOR CO.
Remove the caliper and hang assembly (A).

Fig 28: Removing Caliper
Courtesy of HYUNDAI MOTOR CO.

Fig 29: Hanging Caliper Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the knuckle mounting bolts (A).

Fig 30: Locating Knuckle Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove the steering u-joint mounting bolt (A).

Fig 31: Locating Steering U-Joint Mounting Bolt
Courtesy of HYUNDAI MOTOR CO.
Remove the front muffler heat protector (A).
Remove the front muffler (B).
Tightening torque:

29.4 ~ 39.2 N.m (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft)

Fig 32: Locating Front Muffler Heat Protector And Front Muffler
Courtesy of HYUNDAI MOTOR CO.
Using a floor jack, support the engine and transaxle assembly.
NOTE: After removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them securely with floor jack.
Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.

Fig 33: Supporting Engine And Transaxle Assembly Using Floor Jack
Courtesy of HYUNDAI MOTOR CO.
Remove the sub frame bolts and nuts.
Tightening torque:

Bolt (A), Nut (B):

93.2 ~ 117.7 N.m (9.5 ~ 12.0 kgf.m, 68.7 ~ 86.8 lbf.ft)

Fig 34: Locating Sub Frame Bolts And Nuts
Courtesy of HYUNDAI MOTOR CO.
Remove the engine and transaxle assembly by lifting vehicle.
NOTE: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.