Hyundai Coupes/Sedans 1986-1993 Repair Guide

Engine

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See Figure 1 through 8

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Fig. Fig. 1: General Engine Specifications

REMOVAL & INSTALLATION



The manufacturer recommends that the engine and transaxle be removed as a unit on all models.

Tag all hoses, wires, tubes, cables, etc., so you'll remember where they go when it comes time for installation. If you have a camera handy, a couple of preremoval photographs of the engine compartment may also be useful.

The 1993 Scoupe has a different engine/transaxle layout then the 1991-92 models, the engine/transaxle assembly has been reversed. The removal and installation procedures, as well as all torque specifications are the same for all years of the Scoupe.

All Models Except Sonata V6

See Figures 2, 3, 4, 5, 6 and 7

The factory recommends that the engine and transaxle be removed as a unit. Slight variations in this procedure may occur due to extra connections, etc., but the basic procedure will cover all 4 cylinder engines.

  1. If equipped with fuel injection, relieve the fuel system pressure as follows:
    1. Turn the ignition to the OFF position.
    2.  
    3. Loosen the fuel filler cap to release fuel tank pressure.
    4.  
    5. Disconnect the fuel pump harness connector located under the rear seat cushion on Elantra or in the area of the fuel tank on the remaining models.
    6.  
    7. Start the vehicle and allow it to run until it stalls from lack of fuel. Turn the key to the OFF position.
    8.  
    9. Disconnect the negative battery cable, then reconnect the fuel pump connector.
    10.  

  2.  
  3. Matchmark the hood and hinges and remove the hood assembly. Remove the air cleaner assembly and all adjoining air intake duct work.
  4.  
  5. Remove the under cover if equipped.
  6.  
  7. Disconnect the purge control vacuum hose from the purge valve. Remove the purge control valve mounting bracket. Remove the windshield washer reservoir, radiator tank and carbon canister.
  8.  
  9. Drain the coolant from the radiator. Disconnect the upper and lower radiator hoses and then remove the radiator assembly with the electric cooling fan attached. Be sure to disconnect the fan wiring harness prior to removal.
  10.  
  11. Disconnect the electrical connectors for the back-up lights and engine harness, located near the battery tray. If equipped with a 5 speed transaxle, disconnect the select control valve connector. Disconnect the alternator harness connectors and the oil pressure sending unit.
  12.  
  13. Label and disconnect the automatic transaxle oil cooler hoses. Avoid spilling oil and cap the openings.
  14.  
  15. Label and disconnect all low tension wires and the one high tension wire going to the coil from the distributor. Disconnect the engine ground.
  16.  
  17. Disconnect the brake booster vacuum hose at the intake manifold.
  18.  
  19. Disconnect the fuel supply, return and vapor hoses at the side of the engine. Before disconnecting the fuel supply and return lines, wrap shop towels around the fuel fitting that is being disconnected to absorb any fuel spray caused by residual pressure in the lines.
  20.  
  21. Disconnect the heater hoses from the side of the engine. Disconnect the accelerator cable at the engine side.
  22.  
  23. Disconnect the clutch control cable for manual transaxle or transaxle shifter control cable for automatic transaxle from the transaxle.
  24.  
  25. Unscrew and disconnect the speedometer cable at the transaxle.
  26.  
  27. Remove the air conditioner drive belt and the air conditioning compressor. Leave the hoses attached. Do not discharge the system. Wire the compressor aside.
  28.  
  29. Raise and safely support the vehicle. Remove the splash shield. Remove the drain plug and drain the transaxle fluid. Disconnect the exhaust pipe at the manifold and suspend the pipe securely with wire.
  30.  
  31. If equipped with a manual transaxle, remove the shift control rod and extension rod.
  32.  
  33. Disconnect the stabilizer bar at both lower control arms. Remove the bolts that attach the lower control arms to the body on either side. Support the arms from the body.
  34.  
  35. Remove the front halfshafts. Then, seal off the openings in the transaxle to prevent damage caused by the introduction of foreign substances into the transaxle. Be sure to replace the circlips holding the halfshafts in the transaxle during assembly.
  36.  
  37. Attach an engine lift, via chains or cables, to both the engine lifting hooks. Put just a little tension on the cables. Then, remove the nut and bolt from the front roll stopper; unbolt the brace from the top of the engine damper.
  38.  
  39. Separate the rear roll stopper from the No. 2 crossmember. Remove the attaching nut from the left mount insulator bolt, but do not remove the bolt.
  40.  
  41. Raise the engine just enough that the lifting device is supporting its weight. Check that everything is disconnected from the engine.
  42.  
  43. Remove the blind cover from the inside of the right fender inner shield. Remove the transaxle mounting bracket bolts.
  44.  
  45. Remove the left mount insulator bolt. Then, press downward on the transaxle while lifting the engine/transaxle assembly to guide it up and out of the vehicle.
  46.  

Make sure the transaxle does not hit the battery bracket during engine and transaxle removal.

To install:
  1. Using a lifting device, lower the engine and transaxle carefully into position and loosely install the mounting bolts. Temporarily tighten the front and rear roll control rods mounting bolts. Lower the full weight of the engine and transaxle onto the mounts and tighten the nuts and bolts. Loosen and retighten the roll control rods.
  2.  
  3. Install the transaxle mounting bracket bolts. Install the blind cover to the inside of the right fender inner shield.
  4.  
  5. Assemble the rear roll stopper to the No. 2 crossmember. Install retaining nut and bolt.
  6.  
  7. Install new circlips on the halfshafts and install in position.
  8.  
  9. Attach the lower control arms to the body on either side. Connect the stabilizer bar to both lower control arms.
  10.  
  11. If equipped with a manual transaxle, install the shift control rod and extension rod.
  12.  
  13. Raise the vehicle and support it safely. Connect the exhaust pipe at the manifold. Install the splash shield.
  14.  
  15. Connect the speedometer cable at the transaxle. Connect the air conditioning compressor to the mounting bracket.
  16.  
  17. Install the clutch control cable, for manual transaxle, or shifter control cable, for automatic transaxle, to the transaxle.
  18.  
  19. Lower the vehicle. Connect the heater hoses to the engine. Connect the accelerator cable at the engine side.
  20.  
  21. Connect the fuel supply, return and vapor hoses with new O-rings installed.
  22.  
  23. Connect the brake booster vacuum hose at the intake manifold.
  24.  
  25. Connect all low tension wires and the high tension wire going to the coil from the distributor. Connect the engine ground and the fuel injectors.
  26.  
  27. Connect the automatic transaxle oil cooler hoses.
  28.  
  29. Connect the electrical connectors for the back-up lights and engine harness, located near the battery tray. If equipped with 5 speed, connect the select control valve connector. Connect the alternator harness connectors and the oil pressure sending unit.
  30.  
  31. Install the radiator and electric cooling fan assembly. Connect the upper and lower radiator hoses.
  32.  
  33. Fill all fluids to the proper levels. Adjust the transaxle control cables, accessory drive belts and accelerator linkages as required. Reconnect the negative battery cable.
  34.  
  35. Start the engine and check for leaks as well as proper gauge operation. Allow the vehicle to reach normal operating temperature and recheck all fluid levels.
  36.  
  37. Replace the hood making sure to align the matchmarks made during removal. Allow the engine to cool and recheck the coolant level.
  38.  

Sonata V6


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Fig. Fig. 2: Engine mounting components-Sonata with 2972cc engine

The factory recommends that the engine and transaxle be removed as a unit.

  1. If equipped with fuel injection, relieve the fuel system pressure as follows:
    1. Turn the ignition to the OFF position.
    2.  
    3. Loosen the fuel filler cap to release fuel tank pressure.
    4.  
    5. Disconnect the fuel pump harness connector normally located under the vehicle towards the rear of the fuel tank.
    6.  
    7. Start the vehicle and allow it to run until it stalls from lack of fuel. Turn the key to the OFF position.
    8.  
    9. Disconnect the negative battery cable, then reconnect the fuel pump connector.
    10.  

  2.  
  3. Remove the under cover, if equipped.
  4.  
  5. Matchmark the hood and hinges and remove the hood assembly. Remove the air cleaner assembly and all adjoining air intake duct work.
  6.  
  7. Disconnect the fuel supply line, return line and vent hoses. Prior to disconnecting the fuel supply or return lines, wrap shop towels around the fitting that is being disconnected to absorb any fuel spray caused by residual pressure in the lines.
  8.  
  9. Disconnect the backup light, engine, alternator and oil pressure harnesses.
  10.  
  11. Drain the engine coolant.
  12.  
  13. Label and disconnect the transaxle oil cooler lines, radiator hoses and remove the radiator assembly.
  14.  
  15. Disconnect the brake booster, fuel, evaporative canister and heater hoses.
  16.  
  17. Disconnect the accelerator, transaxle, cruise control and speedometer cables.
  18.  
  19. Detach the air conditioning compressor from the mounting bracket and hang out of the way with a piece of wire. Do not disconnect the refrigerant lines.
  20.  
  21. Remove the power steering pump and wire aside.
  22.  
  23. Raise the vehicle and support safely.
  24.  
  25. Remove the oil pan shield and drain the transaxle.
  26.  
  27. Disconnect the front exhaust pipe.
  28.  
  29. Remove the lower arm ball joint and stabilizer bar at the point where it is mounted to the lower arms.
  30.  
  31. Remove the halfshaft from the housing by prying against the transaxle housing with a prybar.
  32.  
  33. Suspend the lower arm and driveshafts aside using wire attached to the vehicle underbody.
  34.  
  35. Attach an engine lifting device to the engine. Raise the engine just enough to take the tension off the engine mounts.
  36.  
  37. Remove the front roll stopper, engine damper and rear roll stopper.
  38.  
  39. Remove the engine mount bolts.
  40.  
  41. Remove the blind plugs from the inside of the right fender shield and remove the transaxle mounting bracket bolts.
  42.  
  43. Remove the left mount insulator bolt.
  44.  
  45. Raise the engine and transaxle slightly and inspect to make sure all cables, hoses and harness connectors are disconnected.
  46.  
  47. While directing the transaxle side downward, lift the engine and transaxle assembly up and out of the vehicle.
  48.  

To install:
  1. While directing the transaxle side downward, direct the engine and transaxle assembly into the vehicle. Install all mounting hardware and control bracket retainers.
  2.  
  3. Tighten the center crossmember-to-body bolts to 43-58 ft. lbs. (58-77 Nm).
  4.  
  5. Once the engine is securely in place, remove the engine lifting device.
  6.  
  7. Connect the lower arm and the remaining suspension components disassembled during engine removal.
  8.  
  9. Install the halfshafts to the transaxle housing. Make sure the new C-clips are fully engaged into the differential assembly.
  10.  
  11. Connect the front exhaust pipe. Refill the transaxle with fluid.
  12.  
  13. Install the oil pan shield and lower the vehicle.
  14.  
  15. Install the power steering pump.
  16.  
  17. Reconnect the fuel lines using new O-rings where required.
  18.  
  19. Install the air conditioning compressor to the mounting bracket.
  20.  
  21. Connect the accelerator, transaxle, cruise control and speedometer cables.
  22.  
  23. Connect the brake booster, fuel, evaporative canister and heater hoses.
  24.  



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Fig. Fig. 3: 1986-89 Excel engine mounting components-manual transaxle



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Fig. Fig. 4: 1986-89 Excel engine mounting components-automatic transaxle



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Fig. Fig. 5: 1990 Excel engine mounting components

  1. Install the radiator. Connect the transaxle oil cooler lines and radiator hoses.
  2.  
  3. Refill the engine coolant.
  4.  
  5. Connect the backup light, engine, alternator and oil pressure harnesses.
  6.  
  7. Connect the negative battery cable. Install the air cleaner assembly.
  8.  
  9. Start the engine and check for leaks. Allow the engine to run until normal operating temperature is reached and recheck all fluid levels.
  10.  
  11. Replace the hood making sure to align the matchmarks made during removal. Allow the engine to cool and recheck the coolant level.
  12.  



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Fig. Fig. 6: Engine mounting components-Sonata with 1997cc and 2351cc engines



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Fig. Fig. 7: Engine mounting components-Elantra



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Fig. Fig. 8: Engine mounting components-Scoupe

 
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