Hyundai Santa Fe 2001-05

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Removal & Installation



2.4L Engine And 2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery and air cleaner assembly.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the transaxle fluid.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Disconnect the following electrical connections:

    Starter
     
    Alternator
     
    Throttle Position Sensor (TPS)
     
    Power steering switch connector
     
    Oil pressure gauge connector
     
    Back-up lamp switch connector
     
    A/T solenoid inhibitor switch connector
     
    Coolant Temperature Sensor (CTS)
     
    Ignition coil
     
    Idle Speed Control (ISC) valve connector
     
    Manifold Absolute Pressure (MAP) sensor
     
    Oxygen (O 2 S) sensor connector
     

  14.  
  15. If equipped with an automatic transmission, disconnect the oil cooler lines.
  16.  
  17. Remove or disconnect the following:

    Radiator hoses from the engine
     
    Radiator
     
    Engine ground
     
    Brake vacuum hose
     
    Heater hoses at the engine
     
    Throttle cable at the engine
     
    Cruise control cable at the engine, if equipped
     
    Main fuel line at the supply/return pipe
     
    Speedometer cable at the transaxle
     
    Clutch or control cable from the transaxle
     
    Power steering hoses from the pump
     
    Steering dust cover in the engine compartment
     
    Gear box universal joint bolt
     
    Front wheel
     
    Brake caliper and support with wire
     
    Strut lower bolt
     
    Front muffler bolts
     
    Transaxle control rod and extension rod, if equipped with a manual transmission
     

  18.  
  19. Support the transmission with a jack using the special attachment shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Attach the special tool to the transmission jack and support the transmission

  20.  
  21. Make sure all cable, harness connectors and hoses are disconnected from the engine and transmission.

    Engine and transaxle mounting brackets
     
    Sub frame bolts
     
    Drive shaft
     

  22.  
  23. Lower the engine and transaxle assembly enough so the front and rear roll stoppers can be removed.
  24.  
  25. Remove the engine assembly
  26.  

To install:  

  1. Installation is the reverse of removal but please note the following steps:

    Tighten the roll stopper bolts to 36-47 ft. lbs. (50-65 Nm)
     
    Tighten the transaxle mounting bracket bolts to 65-80 ft. lbs. (90-110 Nm)
     
    Tighten the engine mount bracket bolts to 43-58 ft. lbs. (60-80 Nm)
     

  2.  
  3. Fill the engine crankcase to the correct level.
  4.  
  5. Fill the transaxle to the correct level.
  6.  
  7. Fill the cooling system.
  8.  
  9. Fill the power steering system.
  10.  
  11. Start the engine and check for leaks.
  12.  
  13. Check the wheel alignment and adjust as necessary.
  14.  

3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery and engine cover assembly.
  4.  
  5. Remove the battery stay.
  6.  
  7. Remove the air cleaner.
  8.  
  9. Drain the cooling system.
  10.  
  11. Drain the engine oil.
  12.  
  13. Drain the transaxle fluid.
  14.  
  15. Relieve the fuel system pressure.
  16.  
  17. Disconnect the following electrical connections:

    Alternator
     
    Starter
     
    Power steering switch connector
     
    Oil pressure gauge connector
     
    A/C switch
     
    Fuel injector connectors
     
    Back-up lamp switch connector
     
    A/T solenoid inhibitor switch connector
     
    Ignition coils
     
    Power TR selector connector
     
    Idle Speed Control (ISC) valve connector
     
    AFS and ATS connectors
     
    Oxygen (O2S) sensor connector
     

  18.  
  19. Remove any remaining electrical connections that would interfere with engine removal.
  20.  
  21. If equipped with an automatic transmission, disconnect the oil cooler lines.
  22.  
  23. Disconnect the radiator hoses from the engine.
  24.  
  25. Disconnect the engine and transaxle grounds.
  26.  
  27. Disconnect the brake booster vacuum hose.
  28.  
  29. Disconnect the heater hoses from the engine.
  30.  
  31. Disconnect the fuel delivery and return lines.
  32.  
  33. Disconnect the speedometer cable from the transaxle.
  34.  
  35. Disconnect the control cable from the transaxle.
  36.  
  37. Disconnect the power steering hose from the engine mount bracket.
  38.  
  39. Disconnect the steering dust cover in the engine compartment.
  40.  
  41. Disconnect the gear box universal joint bolt. Mark the locations prior to removal to aid in installation.
  42.  
  43. Remove the front wheel.
  44.  
  45. Remove the brake caliper and support with wire.
  46.  
  47. Remove the strut lower bolt and disconnect the strut from the knuckle.
  48.  
  49. Remove the wheel speed sensor from the knuckle.
  50.  
  51. Remove the front muffler bolts.
  52.  
  53. Support the transmission with a jack using the special attachment shown in the accompanying illustration.
  54.  
  55. Make sure all cable, harness connectors and hoses are disconnected from the engine and transmission.
  56.  
  57. Remove the engine and transaxle mounting brackets.
  58.  
  59. Remove the sub frame bolts.
  60.  
  61. Lower the transaxle side down, then lift the engine and transaxle assembly from the vehicle..
  62.  
  63. Installation is the reverse of removal but please note the following steps:
    1. Tighten the front roll stopper-to-transaxle bolts to 43-58 ft. lbs. (60-80 Nm).
    2.  
    3. Tighten the front roll stopper insulator bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    4.  
    5. Tighten the front roll stopper-to-subframe bolts to 43-58 ft. lbs. (60-80 Nm).
    6.  
    7. Tighten the rear roll stopper-to-subframe bolts to 43-58 ft. lbs. (60-80 Nm).
    8.  
    9. Tighten the rear roll stopper-to-transaxle bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    10.  
    11. Tighten the rear roll stopper insulator bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    12.  
    13. Tighten the transaxle mounting sub-bracket bolts to 43-58 ft. lbs. (60-80 Nm).
    14.  
    15. Tighten the transaxle mounting bracket bolts to 43-58 ft. lbs. (60-80 Nm).
    16.  
    17. Tighten the transaxle mounting insulator bolt to 65-80 ft. lbs. (90-110 Nm).
    18.  
    19. Tighten the engine mount bracket bolts to 43-58 ft. lbs. (60-80 Nm).
    20.  
    21. Tighten the engine mount insulator bolt to 65-80 ft. lbs. (90-110 Nm).
    22.  

  64.  
  65. Fill the engine crankcase to the correct level.
  66.  
  67. Fill the transaxle to the correct level.
  68.  
  69. Fill the cooling system.
  70.  
  71. Fill the power steering system.
  72.  
  73. Start the engine and check for leaks.
  74.  
  75. Check the wheel alignment and adjust as necessary.
  76.  


    Click image to see an enlarged view

    Fig. Attach the special tool to the transmission jack and support the transmission


  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery and engine cover assembly.
  4.  
  5. Remove the battery stay.
  6.  
  7. Remove the air cleaner.
  8.  
  9. Drain the cooling system.
  10.  
  11. Drain the engine oil.
  12.  
  13. Drain the transaxle fluid.
  14.  
  15. Relieve the fuel system pressure.
  16.  
  17. Disconnect the following electrical connections:

    Alternator
     
    Starter
     
    Power steering switch connector
     
    Oil pressure gauge connector
     
    A/C switch
     
    Fuel injector connectors
     
    Back-up lamp switch connector
     
    A/T solenoid inhibitor switch connector
     
    Ignition coils
     
    Power TR selector connector
     
    Idle Speed Control (ISC) valve connector
     
    AFS and ATS connectors
     
    Oxygen (O 2 S) sensor connector
     

  18.  
  19. Remove any remaining electrical connections that would interfere with engine removal.
  20.  
  21. If equipped with an automatic transmission, disconnect the oil cooler lines.
  22.  
  23. Disconnect the radiator hoses from the engine.
  24.  
  25. Disconnect the engine and transaxle grounds.
  26.  
  27. Disconnect the brake booster vacuum hose.
  28.  
  29. Disconnect the heater hoses from the engine.
  30.  
  31. Disconnect the fuel delivery and return lines.
  32.  
  33. Disconnect the speedometer cable from the transaxle.
  34.  
  35. Disconnect the control cable from the transaxle.
  36.  
  37. Disconnect the power steering hose from the engine mount bracket.
  38.  
  39. Disconnect the steering dust cover in the engine compartment.
  40.  
  41. Disconnect the gear box universal joint bolt. Mark the locations prior to removal to aid in installation.
  42.  
  43. Remove the front wheel.
  44.  
  45. Remove the brake caliper and support with wire.
  46.  
  47. Remove the strut lower bolt and disconnect the strut from the knuckle.
  48.  
  49. Remove the wheel speed sensor from the knuckle.
  50.  
  51. Remove the front muffler bolts.
  52.  
  53. Support the transmission with a jack using the special attachment shown in the accompanying illustration.
  54.  
  55. Make sure all cable, harness connectors and hoses are disconnected from the engine and transmission.

    Click image to see an enlarged view

    Fig. Attach the special tool to the transmission jack and support the transmission

  56.  
  57. Remove the engine and transaxle mounting brackets.
  58.  
  59. Remove the sub frame bolts.
  60.  
  61. Lower the transaxle side down, then lift the engine and transaxle assembly from the vehicle..
  62.  

To install:  

  1. Installation is the reverse of removal but please note the following steps:
    1. Tighten the front roll stopper-to-transaxle bolts to 43-58 ft. lbs. (60-80 Nm).
    2.  
    3. Tighten the front roll stopper insulator bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    4.  
    5. Tighten the front roll stopper-to-subframe bolts to 43-58 ft. lbs. (60-80 Nm).
    6.  
    7. Tighten the rear roll stopper-to-subframe bolts to 43-58 ft. lbs. (60-80 Nm).
    8.  
    9. Tighten the rear roll stopper-to-transaxle bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    10.  
    11. Tighten the rear roll stopper insulator bolt and nut to 36-47 ft. lbs. (50-65 Nm).
    12.  
    13. Tighten the transaxle mounting sub-bracket bolts to 43-58 ft. lbs. (60-80 Nm).
    14.  
    15. Tighten the transaxle mounting bracket bolts to 43-58 ft. lbs. (60-80 Nm).
    16.  
    17. Tighten the transaxle mounting insulator bolt to 65-80 ft. lbs. (90-110 Nm).
    18.  
    19. Tighten the engine mount bracket bolts to 43-58 ft. lbs. (60-80 Nm).
    20.  
    21. Tighten the engine mount insulator bolt to 65-80 ft. lbs. (90-110 Nm).
    22.  

  2.  
  3. Fill the engine crankcase to the correct level.
  4.  
  5. Fill the transaxle to the correct level.
  6.  
  7. Fill the cooling system.
  8.  
  9. Fill the power steering system.
  10.  
  11. Start the engine and check for leaks.
  12.  
  13. Check the wheel alignment and adjust as necessary.
  14.  

Except 3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery and air cleaner assembly.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the transaxle fluid.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Disconnect the following electrical connections:

    Starter
     
    Alternator
     
    Throttle Position Sensor (TPS)
     
    Power steering switch connector
     
    Oil pressure gauge connector
     
    Back-up lamp switch connector
     
    A/T solenoid inhibitor switch connector
     
    Coolant Temperature Sensor (CTS)
     
    Ignition coil
     
    Idle Speed Control (ISC) valve connector
     
    Manifold Absolute Pressure (MAP) sensor
     
    Oxygen (O2S) sensor connector
     

  14.  
  15. If equipped with an automatic transmission, disconnect the oil cooler lines.
  16.  
  17. Remove or disconnect the following:

    Radiator hoses from the engine
     
    Radiator
     
    Engine ground
     
    Brake vacuum hose
     
    Heater hoses at the engine
     
    Throttle cable at the engine
     
    Cruise control cable at the engine, if equipped
     
    Main fuel line at the supply/return pipe
     
    Speedometer cable at the transaxle
     
    Clutch or control cable from the transaxle
     
    Power steering hoses from the pump
     
    Steering dust cover in the engine compartment
     
    Gear box universal joint bolt
     
    Front wheel
     
    Brake caliper and support with wire
     
    Strut lower bolt
     
    Front muffler bolts
     
    Transaxle control rod and extension rod, if equipped with a manual transmission
     

  18.  
  19. Support the transmission with a jack using the special attachment shown in the accompanying illustration.
  20.  
  21. Make sure all cable, harness connectors and hoses are disconnected from the engine and transmission.

    Engine and transaxle mounting brackets
     
    Sub frame bolts
     
    Drive shaft
     

  22.  
  23. Lower the engine and transaxle assembly enough so the front and rear roll stoppers can be removed.
  24.  
  25. Remove the engine assembly
  26.  
  27. Installation is the reverse of removal but please note the following steps:

    Tighten the roll stopper bolts to 36-47 ft. lbs. (50-65 Nm)
     
    Tighten the transaxle mounting bracket bolts to 65-80 ft. lbs. (90-110 Nm)
     
    Tighten the engine mount bracket bolts to 43-58 ft. lbs. (60-80 Nm)
     

  28.  
  29. Fill the engine crankcase to the correct level.
  30.  
  31. Fill the transaxle to the correct level.
  32.  
  33. Fill the cooling system.
  34.  
  35. Fill the power steering system.
  36.  
  37. Start the engine and check for leaks.
  38.  
  39. Check the wheel alignment and adjust as necessary.
  40.  


    Click image to see an enlarged view

    Fig. Attach the special tool to the transmission jack and support the transmission


 
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