Engine And Transaxle Assembly: 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 bad connection.
Inspection the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

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

Fig 1: Locating Terminals And Battery
Courtesy of HYUNDAI MOTOR CO.
Remove the engine cover.
Remove the air duct (A).
Tightening torque:

7.8 ~ 10.8N.m (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0lb-ft)

Fig 2: Locating Air Duct
Courtesy of HYUNDAI MOTOR CO.
Remove the radiator cap to speed daring.
Loosen the radiator drain plug (A) and drain engine coolant.

Fig 3: Locating Radiator Drain Plug
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Remove the air cleaner assembly.
1. Disconnect the power train control module (PCM) connector (A).
2. Disconnect the intake hose (B).
3. Remove the air cleaner assembly (C).
Tightening torque:

Hose clamp:

2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 2.6lb-ft)

Mounting bolt:

7.8 ~ 10.8N.m (0.8 ~ 1.1kgf.m,

5.8 ~ 8.0lb-ft)

Fig 4: Locating Power Train Control Module Connector, Intake Hose And Air Cleaner Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the battery tray (A) and the front connector (B).
Tightening torque:

8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)

Fig 5: Locating Battery Tray And Front Connector
Courtesy of HYUNDAI MOTOR CO.
Remove the upper radiator hose (A) and lower radiator hose (B).

Fig 6: Locating Upper Radiator Hose And Lower Radiator Hose
Courtesy of HYUNDAI MOTOR CO.
Disconnect the auto transaxle fluid (ATF) hose (A).

Fig 7: Locating Auto Transaxle Fluid Hose
Courtesy of HYUNDAI MOTOR CO.
Remove the heater hose (A).

Fig 8: Locating Heater Hose
Courtesy of HYUNDAI MOTOR CO.
Remove the junction box cover.
Disconnect the terminals (A) from the fuse box.
Tightening torque:

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

Fig 9: Locating Fuse Box Terminals
Courtesy of HYUNDAI MOTOR CO.
After removing the mounting bolts, remove the relay and fuse assembly (A).
Tightening torque:

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

Fig 10: Identifying Relay And Fuse Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove the connector wiring (A) and the engine wiring (B).

Fig 11: Locating Connector Wiring And Engine Wiring
Courtesy of HYUNDAI MOTOR CO.
Remove the engine control side ground (A) and, the transaxle control side one (B).
Tightening torque:

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

Fig 12: Locating Engine Control Side Ground And Transaxle Control Side One
Courtesy of HYUNDAI MOTOR CO.
Remove the fuel inlet from delivery pipe (A) and brake booster vacuum hose (B).

Fig 13: Locating Fuel Inlet From Delivery Pipe And Brake Booster Vacuum Hose
Courtesy of HYUNDAI MOTOR CO.
Disconnect the accelerator cable (C) and the auto-cruise cable (D) from the cylinder head cover.

Fig 14: Locating Accelerator Cable And Auto-Cruise Cable
Courtesy of HYUNDAI MOTOR CO.
Remove the transaxle wire and control cable. (Refer to MANUAL TRANSAXLE (M5CF2) or AUTOMATIC TRANSAXLE CONTROL SYSTEM ).
Remove the high & low pressure pipe. (Refer to AIR CONDITIONER COMPRESSOR ).
Remove the steering u-joint mounting bolt (A).

Fig 15: Locating Steering U-Joint Mounting Bolt
Courtesy of HYUNDAI MOTOR CO.
Install the SST (09200-38001, 09200-1C000), the engine support fixture and the adapter, on the engine and transaxle assembly.

Fig 16: Identifying SST (09200-38001, 09200-1C000)
Courtesy of HYUNDAI MOTOR CO.
Remove the engine mounting bracket (A) by removing the bolts (B, C) and nuts (D) and ground line (F).
Tightening torque:

Bolt (B):

63.7 ~ 83.3N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

Bolt (C), Nuts (D):

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

Bolt (E):

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

Fig 17: Locating Engine Mounting Bracket, Bolts, Nuts And Ground Line
Courtesy of HYUNDAI MOTOR CO.
Remove the transaxle mounting bracket (A) and the ground line (B).
Tightening torque:

A : 88.2 ~ 107.8N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.5lb-ft)

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

Fig 18: Locating Transaxle Mounting Bracket And Ground Line
Courtesy of HYUNDAI MOTOR CO.
Remove the front tires.
Disconnect the stabilizer bar link and remove the mounting bolts from the lower arm and the front axles.
Remove the front muffler (A) and disconnect the rear oxygen sensor connector (B).

Fig 19: Locating Front Muffler And Rear Oxygen Sensor Connector
Courtesy of HYUNDAI MOTOR CO.
Remove the sub frame bolts (A).
Tightening torque:

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

Fig 20: Identifying Sub Frame Bolts (1 Of 2)
Courtesy of HYUNDAI MOTOR CO.

Fig 21: Identifying Sub Frame Bolts (2 Of 2)
Courtesy of HYUNDAI MOTOR CO.
Remove the engine support fixture and the adapter.
Jack up the vehicle.