REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5, 6, 7 and 8
The most important part of engine removal is the labeling of components, wires and hoses to be removed or disconnected from the engine. In most cases, the engine will be removed one day and installed several days later. This lapse in time makes it very difficult (even for professional mechanics) to remember where each and every connection must be made. A little time spent labeling and taking photographs of the engine compartment will pay big dividends once the engine is ready for installation.
Hyundai recommends that the engine and transaxle be removed as a single unit on all models.
- Relieve fuel system pressure.
- Disconnect the negative, then the positive battery cable.
- Matchmark the hood and hinges and remove the hood assembly.
- Remove the air cleaner assembly and all adjoining air intake duct work.
- Drain the coolant from the radiator.
- Disconnect the radiator hoses and remove the radiator assembly with the electric cooling fan attached.
Ensure the cooling fan wiring harness is disconnected prior to removal.
- Label, disconnect and plug all vacuum, fuel, emission, fluid and coolant lines on the engine and transaxle.
- Label and disconnect all electrical harnesses on the engine and transaxle.
- If equipped with a manual, disconnect clutch control cable.
- Disconnect shift control rod on manual transaxle or the shift control cable on automatic transaxle.
- Disconnect the accelerator and speedometer cables.
- Remove the air conditioner compressor and set it aside in the engine compartment.
- Remove the power steering pump and set it aside in the engine compartment.
- Raise and support the vehicle safely.
- Remove the engine under cover, if equipped.
- Disconnect the exhaust pipe at the manifold and suspend the pipe with wire.
- 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.
- Remove the front halfshafts and seal off the openings to prevent the entry of dirt.
- Lower the vehicle.
- 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.
- Separate the rear roll stopper from the crossmember.
- Remove the nut from the left mount insulator bolt, but do not remove the bolt.
- Raise the engine just enough that the lifting device is supporting its weight.
- Remove the transaxle mounting bracket bolts.
Prior to lifting the engine/transaxle assembly, check that everything is disconnected.
- 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.
Ensure the engine/transaxle assembly does not hit anything in the engine compartment during removal.To install:
- Installation is the reverse of removal. Please note the following important steps:
- After installing the engine/transaxle assembly, temporarily tighten the front roll stopper.
- The front and rear center member rubber bushings and collar are different.
- After the weight of the engine/transaxle assembly has been put on each mount, tighten the mount to the correct torque.
- Be sure to replace the circlips holding the halfshafts in the transaxle during assembly.
- During assembly, ensure all components, hoses, lines and electrical connectors are installed securely.
- Refill all engine and transaxle fluids.
- Start the engine and allow it to reach operating temperature.
- Check for fluid leaks.
- Check for proper operation of the transaxle, all control cables and all removed or disconnected components.
- Adjust the transaxle control cables, accessory drive belts and accelerator linkages as required.