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.
For release the fuel system pressure before remove the engine assembly, start the engine without fuel pump relay, and then turn off the ignition switch after engine stops.

Remove the engine cover.
Remove the battery and battery tray.
(Refer to "BATTERY ")
Remove the engine room under cover.
(Refer to "ENGINE ROOM UNDER COVER ")
Drain the engine coolant.
(Refer to "COOLANT ")
Disconnect the radiator upper hose (A).

Fig 1: Disconnecting Radiator Upper Hose
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the radiator lower hose (A).

Fig 2: Disconnecting Radiator Lower Hose
Courtesy of HYUNDAI MOTOR AMERICA

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

Fig 3: Installing Radiator Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.
(Refer to "COMPRESSOR ")
Remove the transaxle wire harness connectors and control cable from the transaxle.
(Refer to "MANUAL TRANSAXLE ")

(Refer to "AUTOMATIC TRANSAXLE ")
Disconnect the brake booster vacuum hose (A) and the heater hoses (B).

Fig 4: Disconnecting 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 5: Installing Heater Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).

Fig 6: Disconnecting Fuel Hose And Purge Control Solenoid Valve (PCSV) Hose
Courtesy of HYUNDAI MOTOR AMERICA
Remove the engine wirings from the engine room.
1. Remove the (+) cable nut (A).
  Tightening torque:
  
  6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
2. Disconnect the EMS block (B).
3. Disconnect the fuse box connector (C).
4. Disconnect the battery sensor connector (D).
5. Remove the ground bolts (E).
  Tightening torque:
  
  10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
6. Remove the engine wirings from the engine room.
Fig 7: Disconnecting Fuse Box Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the front muffler.
(Refer to "MUFFLER ")
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)

Bolts (C):

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

Fig 8: Removing Roll Rod Bracket
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 9: Removing Roll Rod Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Remove the sub frame.
(Refer to "SUB FRAME ")
NOTE:
- After removing the sub frame mounting bolt, 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 cable (A).
Tightening torque:

10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
Remove the engine mounting support bracket (B).
Tightening torque

C: 28.8 ~ 73.5 N.m (6.0 ~ 7.5 kgf.m, 43.3 ~ 54.2 lb-ft)

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

Fig 10: Removing Engine Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ground line (A).

Fig 11: Disconnecting Ground Line
Courtesy of HYUNDAI MOTOR AMERICA
Remove the service cover (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 12: Removing Service Cover
Courtesy of HYUNDAI MOTOR AMERICA

Fig 13: Loosening Transaxle Mounting Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Remove the engine and transaxle assembly by lifting vehicle.
CAUTION: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.