Engine & Transaxle Assembly: Removal

WARNING: This page is about a different variant/trim than selected.

Remove the battery.
Detach the air cleaner

Fig 1: Identifying Air Cleaner
Courtesy of HYUNDAI MOTOR CO.
Disconnect the engine harness connectors.
1. Engine wiring connectors (alternator, starter, etc.)
2. TPS connector
3. Power steering switch connector, oil pressure gauge connector.
4. Back up lamp switch connector.
5. A/T solenoid, inhibitor switch connector.
6. Coolant temperature sensor.
7. Ignition coil, power TR connector.
8. Idle speed control valve (ISC) connector.
9. MAP and ATS connectors.
10. Oxygen sensor connector.
  
  Fig 2: View Transmission Range Sensor
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 3: View Engine Coolant Temperature Sensor
  Courtesy of HYUNDAI MOTOR CO.
Drain the engine coolant.
For a vehicle with automatic transaxles, disconnect the transaxle oil cooler hoses.
NOTE:
- When disconnecting hoses, make identification marks to avoid making any mistake when installing them again.
CAUTION:
- Be careful not to spill any of oil or fluid out of the hoses. Plug the opening to prevent the entry of foreign material.
Disconnect the radiator upper and lower hoses on the engine side then remove the radiator assembly.

Fig 4: Removing Upper Radiator Hose
Courtesy of HYUNDAI MOTOR CO.
Disconnect the engine ground.
Disconnect the brake booster vacuum hose.

Fig 5: Identifying Brake Booster Vacuum Hose
Courtesy of HYUNDAI MOTOR CO.
Disconnect the heater hoses (inlet and outlet) on the engine side.
Disconnect the accelerator cable at the engine side.

Fig 6: Identifying Accelerator Cable
Courtesy of HYUNDAI MOTOR CO.
Using a special tool, remove the main fuel line at the delivery pipe (supply/return).
Disconnect the speedometer cable from the transaxle.
Disconnect the clutch cable or control cable from the transaxle.

Fig 7: Identifying Clutch Cable Or Control Cable
Courtesy of HYUNDAI MOTOR CO.
Disconnect the power steering hose and return hose from the pump.

Fig 8: Identifying Power Steering Hoses
Courtesy of HYUNDAI MOTOR CO.
Detach the steering dust cover in the engine compartment and then disconnect the gear box universal joint bolt.
NOTE: Make sure to make identification marks between the universal joint and the gear box for reassembly.

Fig 9: Identifying Steering Column Through Floor Board Location
Courtesy of HYUNDAI MOTOR CO.
Raise the vehicle and then remove the front tire.
Attaching the wheel speed sensor and caliper to the body, disconnect the lower arm and the fork, and then separate the upper arm and knuckle.

Fig 10: Securing Brake Caliper & Identifying Wheel Knuckle Bolts
Courtesy of HYUNDAI MOTOR CO.
Drain the transaxle oil.

Fig 11: Identifying Transaxles Drain Plugs
Courtesy of HYUNDAI MOTOR CO.
Remove the front muffler bolts.
Remove the transaxle control rod and extension rod (M/T only).

Fig 12: Identifying Transaxle Control Rod & Extension Rod
Courtesy of HYUNDAI MOTOR CO.
Put the special fixture on the T/M jack and then adjust it to the sub-frame.
NOTE: Check that all the cables, harness connector and hose are disconnected from the engine and transaxle assembly.

Fig 13: Identifying T/M Jack
Courtesy of HYUNDAI MOTOR CO.
Remove the engine mounting bracket and the transaxle mounting bracket.

Fig 14: Identifying Engine Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.

Fig 15: Identifying Transaxle Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
Remove the sub-frame installation bolts.

Fig 16: Identifying Sub-Frame Bolts
Courtesy of HYUNDAI MOTOR CO.
Using the special tool 09624 - 38100, remove the cross member stub bolt.

Fig 17: Removing Cross Member Stub Bolt
Courtesy of HYUNDAI MOTOR CO.

With holding the stud bolt using a special tool in order not to loosen the stud bolt, remove the lock nut using a ring wrench.
After removing the drive shaft, lower the engine and transaxle assembly on the jack then, remover the front roll stopper and the rear roll stopper.

Fig 18: Removing Engine
Courtesy of HYUNDAI MOTOR CO.
Remove the engine and transaxle assembly as a unit.