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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.
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
Disconnect the battery terminals (A). Disconnect the negative terminal first.
Tightening torque:

(+) terminal:

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

(-) terminal:

4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

Fig 2: Identifying Battery Terminals
Courtesy of HYUNDAI MOTOR AMERICA
Remove the air cleaner assembly.
1. Remove the air duct (A).
2. Disconnect the breather hose (B).
3. Disconnect the air intake hose (C) and then remove the air cleaner assembly (D).
  Tightening torque
  
  Hose clamp bolt:
  
  2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  Fig 3: Identifying Air Cleaner Assembly Components
  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 groove of hose must be matched to the protrusion of the throttle body.
  Fig 4: Air Intake Hose
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the battery (A) after removing the mounting bracket.
Tightening torque:

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

Fig 5: Identifying Battery
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ECM connectors (A) and then remove the ECM (B) and the battery tray (C).
Tightening torque

ECM bracket bolt and nut:

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

Battery tray bolts:

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

Fig 6: Identifying ECM, Connectors And Battery Tray
Courtesy of HYUNDAI MOTOR AMERICA
Remove the under covers (A).
Tightening torque:

6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)

Fig 7: Identifying Under Covers
Courtesy of HYUNDAI MOTOR AMERICA
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. (Refer to RADIATOR .
Disconnect the radiator upper hose (A) and lower hose (B).

Fig 8: Identifying Radiator Upper Hose
Courtesy of HYUNDAI MOTOR AMERICA

Fig 9: Identifying Lower Hose
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Install the radiator hoses as shown illustrations.

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

Fig 11: Identifying High & Low Pressure Pipes
Courtesy of HYUNDAI MOTOR AMERICA
Remove the front bumper. (Refer to FRONT BUMPER ).
Remove the rail (A) and the front end module (B).

Fig 12: Identifying Rail And Front End Module
Courtesy of HYUNDAI MOTOR AMERICA
Remove the resonator (A).
Tightening torque:

3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

Fig 13: Identifying Resonator
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the wiring connectors and harness clamps, and remove the wiring and protectors from the cylinder head and intake manifold.
1. The A/C compressor switch connector (A) and the alternator connector (B)
  
  Fig 14: Identifying A/C Compressor Switch Connector And Alternator Connector
  Courtesy of HYUNDAI MOTOR AMERICA
2. The intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B)
  
  Fig 15: Identifying Intake And Exhaust Oil Control Valve Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
3. The ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D)
  
  Fig 16: Identifying Ignition Coil, Injector Extension, Variable Intake System And Purge Control Solenoid Valve Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
4. The FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B), the exhaust CMPS (Camshaft position sensor) connector (C).
  
  Fig 17: Identifying Fuel Pressure Control Valve & Intake And Exhaust Camshaft Position Sensor Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
5. The oxygen sensor connectors (A), the condenser connector (B)
  
  Fig 18: Identifying Oxygen Sensor Connectors And Condenser Connector
  Courtesy of HYUNDAI MOTOR AMERICA
6. The ECTS (Engine coolant temperature sensor) connector (A), the ground (B)
  
  Fig 19: Identifying Engine Coolant Temperature Sensor Connector And Ground
  Courtesy of HYUNDAI MOTOR AMERICA
7. The ETC (Electronic throttle control) connector (A) and the MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (B)
  
  Fig 20: Identifying Electronic Throttle Control And Manifold Absolute Pressure Sensor & Intake Air Temperature Sensor Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
8. The knock sensor connector (A), the CKPS (Crankshaft position sensor) connector (B), the starter connector (C) and the OPS (Oil pressure switch) connector (D).
  
  Fig 21: Identifying Knock Sensor, Crankshaft Position Sensor, Starter And Oil Pressure Switch Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the (+) cable (A) from the fuse/relay box and the front connector (B).

Fig 22: Identifying Fuse/Relay Box (+) Cable
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 23: Identifying Fuel Hose And Purge Control Solenoid Valve Hose
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the brake booster vacuum hose (A) and the heater hose (B).

Fig 24: Identifying Brake Booster Vacuum Hose And Heater Hose
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Install the heater hoses as shown illustrations.

Fig 25: Installing Heater Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to AUTOMATIC TRANSAXLE SYSTEM or MANUAL TRANSAXLE SYSTEM ).
Disconnect the ATF oil cooler hoses (A). (Refer to AUTOMATIC TRANSAXLE ).

Fig 26: Identifying ATF Oil Cooler Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Remove the front muffler (A) after removing the rear oxygen sensor connector from the bracket.
Tightening torque:

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

Fig 27: Identifying Front Muffler
Courtesy of HYUNDAI MOTOR AMERICA
Remove the steering u-joint mounting bolt (A). (Refer to STEERING COLUMN AND SHAFT ).

Fig 28: Identifying Steering U-Joint Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the front wheels. (Refer to WHEEL ).
Remove the lower arms (A). (Refer to FRONT LOWER ARM ).

Fig 29: Identifying Lower Arms
Courtesy of HYUNDAI MOTOR AMERICA
Remove the stabilizer bar links (A). (Refer to FRONT STABILIZER BAR ).

Fig 30: Identifying Stabilizer Bar Links
Courtesy of HYUNDAI MOTOR AMERICA
Remove the tie rod ends (A). (Refer to STEERING GEAR BOX ).

Fig 31: Identifying Tie Rod Ends
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the drive shafts from the axle hubs. (Refer to FRONT DRIVESHAFT ).
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 32: Identifying Roll Rod Bracket
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 33: Identifying Roll Rod Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ground cable (A) and remove the engine mounting support bracket (B).
Tightening torque

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 34: Identifying Engine Mounting Support Bracket, Ground Cable, Mounting Nuts And Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ground cable, and then remove the transaxle mounting bracket bolts (A).
Tightening torque:

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

Fig 35: Identifying Transaxle Mounting Bracket Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Remove the engine and transaxle assembly in the forward direction from the vehicle.

Fig 36: 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.