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Repair procedures: Removal

WARNING: This page is about a different car, the 2011 Hyundai Veracruz. However, it is still accessible from the selected car via links, so may be relevant.

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 battery negative cable (A).

Fig 1: Disconnecting Battery Negative Cable
Courtesy of HYUNDAI MOTOR CO.
Remove the air duct (A).

Fig 2: Identifying Air Duct
Courtesy of HYUNDAI MOTOR CO.
Remove the engine cover (A).

Fig 3: Identifying Engine Cover
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. Remove the intake air hose (C) and air cleaner body (D).
  
  Fig 4: Identifying AFS Connector
  Courtesy of HYUNDAI MOTOR CO.
Remove the RH front wheel.
Remove the under cover (A).

Fig 5: Identifying Under Cover
Courtesy of HYUNDAI MOTOR CO.
Remove the side cover.
Loosen the drain plug and drain the engine coolant.
Drain the engine oil.
Disconnect the ground cable (A) and loosen the power steering hose mounting bolt (B).

Fig 6: Disconnecting Ground Cable
Courtesy of HYUNDAI MOTOR CO.
Remove the surge tank and engine wiring.
1. Disconnect the RH front and rear oxygen sensor connectors (A), the power steering sensor connector (B), the RH injector harness connector (C) and the VIS solenoid valve connector (D).
  
  Fig 7: Identifying Rear Oxygen Sensor Connectors
  Courtesy of HYUNDAI MOTOR CO.
2. Disconnect the RH ignition coil connector.
3. Disconnect the OCV connector (A) and the knock sensor connector (B).
4. Disconnect the LH front oxygen sensor connector (C).
5. Disconnect the alternator connector (D) and the air compressor connector (E).
  
  Fig 8: Identifying OCV Connector
  Courtesy of HYUNDAI MOTOR CO.
6. Disconnect the LH ignition coil connector (A), the injector connector (B), the condenser connector (C) and the ground (D), and remove the wiring harness protector (E).
  
  Fig 9: Identifying LH Ignition Coil Connector
  Courtesy of HYUNDAI MOTOR CO.
7. Disconnect the RH CMPS (A) and the OTS connector (B).
  
  Fig 10: Identifying RH CMPS
  Courtesy of HYUNDAI MOTOR CO.
8. Disconnect the PCSV connector (A), the MAP sensor connector (B) and the PCSV hose.
  
  Fig 11: Identifying PCSV Connector
  Courtesy of HYUNDAI MOTOR CO.
9. Disconnect the ETC connector (A) and the knock sensor connector (B).
  
  Fig 12: Identifying ETC Connector
  Courtesy of HYUNDAI MOTOR CO.
10. Disconnect the water hoses (B) from ETC and PCV (C) hose.
  
  Fig 13: Identifying Water Hoses
  Courtesy of HYUNDAI MOTOR CO.
11. Disconnect the TCU connector (A) and CKP sensor connector (B).
  
  Fig 14: Identifying TCU Connector
  Courtesy of HYUNDAI MOTOR CO.
12. Disconnect the LH rear oxygen sensor connector (A).
  
  Fig 15: Identifying LH Rear Oxygen Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
13. Disconnect brake vacuum hose.
14. Remove the breather pipe assembly (A).
  
  Fig 16: Identifying Breather Pipe Assembly
  Courtesy of HYUNDAI MOTOR CO.
15. Remove the surge tank stays (A).
  
  Fig 17: Identifying Surge Tank Stays (1 Of 2)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 18: Identifying Surge Tank Stays (2 Of 2)
  Courtesy of HYUNDAI MOTOR CO.
16. Remove the connector bracket (A) from the surge tank.
  
  Fig 19: Identifying Connector Bracket
  Courtesy of HYUNDAI MOTOR CO.
17. Remove the surge tank (A).
  
  Fig 20: Identifying Surge Tank
  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 LH cylinder head cover.
  
  Fig 21: Identifying Connector Bracket
  Courtesy of HYUNDAI MOTOR CO.
2. Disconnect the RH ignition coil connector (A), condenser connector (B) and remove the wiring bracket (C).
  
  Fig 22: Identifying RH Ignition Coil Connector
  Courtesy of HYUNDAI MOTOR CO.
3. Remove the LH, RH ignition coil.
4. Remove the LH, RH cylinder head cover (A).
  
  Fig 23: Identifying Cylinder Head Cover
  Courtesy of HYUNDAI MOTOR CO.
Using SST (09215-3C000) remove lower oil pan (A).

Fig 24: Identifying Lower Oil Pan
Courtesy of HYUNDAI MOTOR CO.

NOTE: Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.
Set a jack to the upper oil pan.

Fig 25: Identifying Upper Oil Pan
Courtesy of HYUNDAI MOTOR CO.
Remove the PCM & relay box cover and loosen the relay box mounting bolts.

Fig 26: Identifying Relay Box Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove the engine mounting bracket (A).

Fig 27: Identifying Engine Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
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 28: Identifying Mark On Pulley
  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 29: Identifying Mark Of Camshaft Timing Sprockets
  Courtesy of HYUNDAI MOTOR CO.
  
  NOTE: Do not rotate engine counterclockwise.
Remove the drive belt (A).

Fig 30: Identifying Drive Belt
Courtesy of HYUNDAI MOTOR CO.
Using SST (09231-3C300) remove the crankshaft damper pulley (A).

Fig 31: Identifying Crankshaft Damper Pulley
Courtesy of HYUNDAI MOTOR CO.
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-3C300) to hold the ring gear after removing the starter.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
  1. Remove the front muffler. (Refer to INTAKE AND EXHAUST SYSTEM ).
  2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
    
    Fig 33: Identifying Dust Cover And Transaxle Mounting Bolts
    Courtesy of HYUNDAI MOTOR CO.
  3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
  4. Fasten the two transaxle mounting bolts in the original mounted holes.
    
    Fig 34: Identifying Holder Nuts
    Courtesy of HYUNDAI MOTOR CO.
  5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
    
    Fig 35: Identifying Holder Bolts and Nuts
    Courtesy of HYUNDAI MOTOR CO.
Lift up the engine assembly to using the jack.
Remove the drive belt idler (A).

Fig 36: Identifying Drive Belt Idler
Courtesy of HYUNDAI MOTOR CO.
Remove the drive belt auto tensioner (A).

Fig 37: Identifying Drive Belt Auto Tensioner
Courtesy of HYUNDAI MOTOR CO.
Remove the water pump pulley (A).

Fig 38: Identifying Water Pump Pulley
Courtesy of HYUNDAI MOTOR CO.
Remove the timing chain cover (A). If necessary remove the water pump (B) first.

Fig 39: Identifying Timing Chain Cover
Courtesy of HYUNDAI MOTOR CO.

Fig 40: Identifying Water Pump
Courtesy of HYUNDAI MOTOR CO.

NOTE: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
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.
Install a set pin after compressing the timing chain tensioner.

Fig 41: Installing Set Pin
Courtesy of HYUNDAI MOTOR CO.
Remove the RH cam-to-cam guide (A).

Fig 42: Identifying RH Cam-To-Cam Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).

Fig 43: Identifying RH Timing Chain Auto Tensioner
Courtesy of HYUNDAI MOTOR CO.
Remove the RH timing chain.
Remove the RH timing chain guide (A).

Fig 44: Identifying RH Timing Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pump chain cover (A).

Fig 45: Identifying Oil Pump Chain Cover
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pump chain tensioner assembly (A).

Fig 46: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pump chain guide (A).

Fig 47: Identifying Oil Pump Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the oil pump chain sprocket (A) and oil pump chain (B).

Fig 48: Identifying Oil Pump Chain Sprocket
Courtesy of HYUNDAI MOTOR CO.
Remove the crankshaft sprocket (A) (Oil pump & RH camshaft drive).

Fig 49: Identifying Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.
Install a set pin after compressing the LH timing chain tensioner.

Fig 50: Installing Set Pin
Courtesy of HYUNDAI MOTOR CO.
Remove the LH cam-to-cam guide (A).

Fig 51: 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 52: Identifying LH Timing Chain Auto Tensioner
Courtesy of HYUNDAI MOTOR CO.
Remove the LH timing chain.
Remove the LH timing chain guide (A).

Fig 53: Identifying LH Timing Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Remove the crankshaft sprocket (A) (LH camshaft drive).

Fig 54: Identifying Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.
Remove the tensioner adapter assembly (A).

Fig 55: Identifying Tensioner Adapter Assembly
Courtesy of HYUNDAI MOTOR CO.