Repair procedures: Removal

WARNING: This page is about a different car, the 2012 Hyundai Veloster. 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.
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
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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 (without battery sensor):

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

(-) terminal (with battery sensor):

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 Duct, Breather Hose, Air Intake Hose And Air Cleaner Assembly
  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: Identifying Air Intake Hose Position
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the battery (A) after removing the mounting bracket.
Tightening torque:

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

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

ECM bracket bolts & nut:

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

Battery tray bolts:

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

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

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

Fig 7: Identifying Under Cover
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Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. (Refer to Cooling system in this group)
Disconnect the radiator upper hose (A) and lower hose (B).

Fig 8: Identifying Radiator Upper Hose
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Fig 9: Identifying Radiator Lower Hose
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NOTE: Install the radiator hoses as shown illustrations.

Fig 10: Radiator Hose Installation Position
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Recover the refrigerant and then remove the high pressure pipe and low pressure pipe (A). (Refer to AIR CONDITIONING system in HA Group.)

Fig 11: Identifying High And Low Pressure Pipe
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Disconnect the (+) cable (A) from the fuse/relay box.

Fig 12: Identifying Fuse/Relay Box (+) Cable
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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 13: 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 14: Identifying Intake And Exhaust Oil Control Valve Connector
  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 15: 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) and the exhaust CMPS (Camshaft position sensor) connector (C)
  
  Fig 16: Identifying Fuel Pressure Control Valve, Intake And Exhaust Camshaft Position Sensor Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
5. The oxygen sensor connectors (A) and the condenser connector (B)
  
  Fig 17: Identifying Oxygen Sensor Connectors And Condenser Connector
  Courtesy of HYUNDAI MOTOR AMERICA
6. The ECTS (Engine coolant temperature sensor) connector (A) and the ground line (B)
  
  Fig 18: Identifying Engine Coolant Temperature Sensor Connector And Ground Line
  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 19: 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 front connector (C), the starter connector (D) and the oil pressure connector (E)
  
  Fig 20: Identifying Knock Sensor, Crankshaft Position Sensor, Front Connector, Starter Connector And Oil Pressure Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the transaxle wire harness connectors and control cable from the transaxle.
Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 21: 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 22: Identifying Brake Booster Vacuum Hose And Heater Hose
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Install the heater hoses as shown illustrations.

Fig 23: Identifying Heater Hoses Installation Position
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ATF cooler hoses (A).

Fig 24: Identifying ATF Cooler Hoses
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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 25: Identifying Front Muffler
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Remove the steering u-joint mounting bolt (A).

Fig 26: Identifying Steering U-Joint Mounting Bolt
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Remove the front wheels.
Remove the lower arms (A). (Refer to SS group)

Fig 27: Identifying Lower Arms
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Remove the stabilizer bar links (A).

Fig 28: Identifying Stabilizer Bar Links
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Remove the tie rod ends (A).

Fig 29: Identifying Tie Rod Ends
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Disconnect the drive shafts from the axle hubs.
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 30: Identifying Roll Rod Bracket, Mounting Bolts And Nut
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 31: Identifying Roll Rod Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts.
Tightening torque

Sub frame mounting bolts & nuts:

156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)

Sub frame stay mounting bolts:

44.1 ~ 53.9 N.m (4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft)

Fig 32: Identifying Sub Frame, Mounting Bolts And Nuts
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
- After removing the sub frame mounting bolts and nuts, 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.
Disconnect the ground line (A) and then remove the engine mounting support bracket (B).
Tightening torque

Ground line bolt:

10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)

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

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

Fig 34: Identifying Ground Line And Transaxle Mounting Bracket Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Remove the engine and transaxle assembly (A) by lifting vehicle.

Fig 35: 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.