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: Engine Cover
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the battery terminals (A). The negative terminal first.
Tightening torque

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

(-) terminal: 4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
Remove the air cleaner assembly.
1. Remove the air duct (B).
2. Disconnect the breather hose (C).
3. Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).
  Tightening torque
  
  Hose clamp bolt:
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts:
  
  3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
  
  Fig 2: Breather Hose, Air Intake Hose, Air Cleaner Assembly, Air Duct
  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.
  
  Fig 3: Air Intake Hose
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the battery (A) after removing the mounting bracket (B).
Tightening torque:

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

Fig 4: Battery And Mounting Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ECM connectors (A) and remove the ECM (B).
Tightening torque:

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

Fig 5: ECM And Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Loosen the battery "+" cable bracket mounting bolt (A) and then remove the battery tray (B).
Tightening torque:

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

Fig 6: Battery Cable Bracket Mounting Bolt And Tray
Courtesy of HYUNDAI MOTOR AMERICA
Remove the under covers (A).
Tightening torque:

7.8 ~ 11.8 N.m (0.7 ~ 1.1 kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 7: Under Covers
Courtesy of HYUNDAI MOTOR AMERICA
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to COOLANT )
Disconnect the radiator upper hose (A).

Fig 8: Radiator Upper Hose
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the radiator lower hose (A).

Fig 9: Radiator Lower Hose
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: When installing radiator hoses, install as shown in the illustrations below.

Fig 10: Radiator Hoses Installation Positions
Courtesy of HYUNDAI MOTOR AMERICA
Recover the refrigerant and then remove the high pressure pipe (A) and the low pressure pipe (B). (Refer to REFRIGERANT RECOVERY .)

Fig 11: High And Low Pressure A/C Pipes
Courtesy of HYUNDAI MOTOR AMERICA
Remove the transaxle wire harness connectors, control cable and hoses from the transaxle. (Refer to REMOVAL (M/T)REMOVAL (A/T) )
Disconnect the brake booster vacuum hose (A) and the heater hoses (B).

Fig 12: Brake Booster Vacuum Hose And Heater Hoses
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: When installing the heater hoses, install as shown in illustrations below.

Fig 13: Heater Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 14: Fuel Hose And Purge Control Solenoid Valve Hose
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the "+" cable (A), the fuse box connector (B) and the EMS block (C) from the fuse/relay box and then remove the wiring protector after disconnecting the ground lines (D).

Fig 15: Positive Battery cable, Fuse Box Connector, EMS Block And Ground Lines
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the front oxygen sensor connector (A) and then remove it from the bracket. (ULEV only)

Fig 16: Front Oxygen Sensor Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the front muffler (A).
Tightening torque:

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

Fig 17: Front Muffler
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Disconnect 2 oxygen sensor wiring clips (A) from under body before removing the front muffler.

Fig 18: Oxygen Sensor Wiring Clips
Courtesy of HYUNDAI MOTOR AMERICA
Remove the steering u-joint mounting bolt (A). (Refer to "STEERING GEAR BOX ")

Fig 19: Steering U-Joint Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the steering u-joint mounting bolt (A).
(Refer to "STEERING GEAR BOX ")
Remove the lower arms (A).
(Refer to "FRONT LOWER ARM ")

Fig 20: Lower Arms
Courtesy of HYUNDAI MOTOR AMERICA
Remove the stabilizer bar links (A).
(Refer to "FRONT STABILIZER BAR ")

Fig 21: Stabilizer Bar Links
Courtesy of HYUNDAI MOTOR AMERICA
Remove the tie rod ends (A).
(Refer to "STEERING GEAR BOX ")

Fig 22: Tie Rod Ends
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the drive shafts (A) from the axle hubs.
(Refer to "FRONT DRIVESHAFT ")

Fig 23: Axle Hub And Drive Shaft
Courtesy of HYUNDAI MOTOR AMERICA
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 24: Roll Rod Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Remove the roll rod mounting support bracket (A).
Tightening torque:

44.1 ~ 39.2 N.m (4.5 ~ 6.0 kgf.m, 32.5 ~ 43.4 lb-ft)

Fig 25: 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)

Stay mounting bolts:

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

Fig 26: Sub Frame And Mounting Bolts
Courtesy of HYUNDAI MOTOR AMERICA
CAUTION:
- After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall down, 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 (A):

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 27: Engine Mounting Support Bracket Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ground line (A), and then slowly loosen the transaxle mounting bolts (B).
Tightening torque:

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

Fig 28: Ground Line
Courtesy of HYUNDAI MOTOR AMERICA

Fig 29: Transaxle Mounting Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Lower the engine and transaxle assembly using a floor jack and then remove the engine and transaxle assembly by lifting vehicle.

Fig 30: 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.