Tucson 2006-2008

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 the 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:

    Oil control valve (OCV) connector
     
    Oil temperature sensor connector
     
    Engine coolant temperature (ECT) sensor
     
    Ignition coil connector
     
    Throttle position sensor (TPS) connector
     
    Idle Speed Actuator (ISA) connector
     
    Camshaft position sensor (CMP) connector
     
    Fuel injector connectors
     
    Ground cable from intake manifold
     
    Compressor switch
     
    Front heated oxygen sensors
     
    Crankshaft position (CKP) connector
     
    Oil pressure switch connector
     
    Purge control solenoid valve (PCSV) connector
     

  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
     
    Transaxle wiring harnesses
     
    Transaxle 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 transaxle assembly.
  18.  
  19. Remove or disconnect the following:

    Engine mounting bracket
     
    Transaxle mounting bracket
     
    Sub-frame mounting bolts
     

  20.  
  21. Jack up the vehicle and remove the engine/transaxle 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 the nuts to 118-133 ft. lbs. (160-180 Nm) and the bolts to 52-66 ft. lbs. (70-90 Nm)
     
    Transaxle 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
     
    Transaxle cooler hose
     
    Transaxle 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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