Hyundai_Tucson_2005

Engine

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Removal & Installation




NOTE
Hyundai recommends that the engine and transaxle be removed as a single unit on all models.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the transaxle.
  6.  
  7. Drain the engine oil.
  8.  
  9. Relieve fuel system pressure.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Engine cover
     
    Upper and lower radiator hoses
     
    Heater hoses
     

  12.  
  13. Remove the following engine wiring harnesses:
    1. Oil control valve (OCV) connector
    2.  
    3. Oil temperature sensor connector
    4.  
    5. Engine coolant temperature (ECT) sensor
    6.  
    7. Ignition coil connector
    8.  
    9. Throttle position sensor (TPS) connector
    10.  
    11. Idle Speed Actuator (ISA) connector
    12.  
    13. Camshaft position sensor (CMP) connector
    14.  
    15. Fuel injector connectors
    16.  
    17. Ground cable from intake manifold
    18.  
    19. Compressor switch
    20.  
    21. Front heated oxygen sensors
    22.  
    23. Crankshaft position (CKP) connector
    24.  
    25. Oil pressure switch connector
    26.  
    27. Purge control solenoid valve (PCSV) connector
    28.  

  14.  
  15. Remove or disconnect the following:

    Fuel supply hose
     
    PCSV hose
     
    Brake booster vacuum hose
     
    Throttle cable
     
    Power steering pump
     
    Battery and battery bracket
     
    Transmission wiring harnesses
     
    Transmission cooler hose
     
    Engine splash guard
     
    Front exhaust pipe
     
    ABS wheel speed sensor from front knuckles
     
    Front strut lower mounting bolts
     
    Front calipers
     
    Steering U-joint mounting bolt
     

  16.  
  17. Using a suitable jack, support the engine and transmission assembly.
  18.  
  19. Remove or disconnect the following:

    Engine mounting bracket
     
    Transmission mounting bracket
     
    Sub-frame mounting bolts
     

  20.  
  21. Jack up the vehicle and remove the engine/transmission assembly.
  22.  

To install:

  1. Move the powertrain assembly into position and lower the vehicle into place.
  2.  
  3. Install or connect the following:

    Sub-frame mounting bolts and nuts. Tighten to nuts to 118-133 ft. lbs. (160-180 Nm) and bolts to 52-66 ft. lbs. (70-90 Nm).
     
    Transmission mounting bracket. Tighten to 118-133 ft. lbs. (160-180 Nm).
     
    Engine mounting bracket. Tighten to 118-133 ft. lbs. (160-180 Nm).
     
    Steering U-joint mounting bolt
     
    Front calipers
     
    Front strut lower mounting bolts
     
    ABS wheel speed sensors
     
    Front exhaust pipe
     
    Engine splash guard
     
    Transmission cooler hose
     
    Transmission wiring harness
     
    Battery and battery bracket
     
    Power steering pump
     
    Throttle cable
     
    Brake booster vacuum hose
     
    PCSV hose
     
    Fuel supply hose
     
    Engine wiring harnesses
     
    Heater hoses
     
    Upper and lower radiator hoses
     
    Air intake assembly
     
    Engine cover
     
    Negative battery cable
     

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Fill the transaxle to the correct level.
  8.  
  9. Fill the cooling system to the proper level.
  10.  
  11. Start the engine and check for leaks.
  12.  

 
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