Contents: Removal ⇓ Installation ⇓
Removal
Attention:
- To avoid damage to the painted surfaces of the car body, cover the front fenders of the car with protective covers.
- Be careful when disconnecting hoses, do not spill oil or other liquid.
- Cap any disconnected tubes or hoses to prevent foreign particles from entering.
Note: When disconnecting hoses, always make alignment marks first so that the hoses are in their original position when reconnecting.
1. Remove the battery.
2. Remove the engine noise protection cover.
3. Disconnect the mass air flow sensor connector.
4. Remove the air filter assembly.
5. Disconnect the connectors of the following components from the engine management system wiring harness:
- a) Generator and starter.
- b) Throttle position sensor.
- c) Power steering hydraulic system fluid pressure switch, oil pressure switch.
- d) Reversing light switch.
- d) (Models with automatic transmission) Automatic transmission electromagnetic valve block, starter interlock switch.
- e) Coolant temperature sensor.
- g) Ignition coils and power transistor.
- c) Idle speed control servo drive.
- i) Intake air temperature sensor.
- k) Oxygen sensor.
6. Drain the coolant.
7. (Models with automatic transmission) Disconnect the automatic transmission fluid cooler hoses.
Note: When disconnecting hoses, always mark the hoses first so that the hoses are in their original position when reconnecting.
Attention:
- Be careful when disconnecting hoses, do not spill oil or other liquid.
- Place plugs on disconnected pipes or hoses to prevent foreign particles from entering.
(The basis of the material is information from the website: hyundaibook.ru)
8. Disconnect the upper and lower radiator hoses, then remove the radiator assembly.
9. Disconnect the engine ground wire.
10. Disconnect the brake booster vacuum hose.
11. Disconnect both heater hoses (inlet and outlet) from the engine side.
12. Disconnect the accelerator pedal cable and cruise control cable from the engine side.
13. Before disconnecting the high-pressure fuel hose from the fuel rail, release any residual pressure from the high-pressure fuel lines to prevent fuel splashing.
14. Disconnect the high pressure fuel hose from the fuel rail.
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15. (Models with automatic transmission) Remove the automatic transmission control cable from the gearbox.
16. Disconnect the power steering hydraulic hoses from the power steering pump.
17. In the engine compartment, remove the steering shaft protective boot, then disconnect the steering cardan shaft joint from the steering gear.
Note: Before removal, be sure to apply relative position marks to the steering propeller shaft joint and steering gear assembly.
18. Raise the vehicle using a lift and remove the front wheels.
19. Remove the caliper assembly from the steering knuckle. Hang the caliper on the front suspension strut with wire (not by the brake hose).
20. Disconnect the wheel drive shafts from the steering knuckle.
The procedure for removing the wheel drive shaft is given in the chapter "Drive shafts".
21. If necessary, remove the front suspension strut.
22. Remove the drain plug and drain the oil from the manual transmission or the working fluid from the automatic transmission.
Manual transmission. |
Automatic transmission. |
23. Loosen the exhaust system inlet pipe mounting bolts.
Note: After disconnecting the exhaust pipe from the exhaust manifold, hang it with wire to the car body.
24. (Manual transmission models) Remove the gear selector cable and the gear shift cable. Remove the clutch slave cylinder.
25. Install special devices on the car. Using chains or cables, secure the engine to the crossbar by the mounting brackets and hang it on the lift.
26. Slowly lift the engine to relieve the engine and gearbox assembly from the mounts and temporarily leave it suspended.
Caution: Make sure that all cables, wires (electrical connectors), hoses, etc. are disconnected from the engine.
27. Attach the special device to the transmission telescopic stand, then adjust it to the subframe.
Note: Make sure that all cables, wires (electrical connectors), hoses, etc. are disconnected from the engine and transmission assembly.
28. Remove the side engine support.
29. Loosen the bolt securing the gearbox support to the support bracket.
30. Unscrew the subframe mounting bolts.
31. Disconnect the drive shafts from the gearbox, then lower the engine and gearbox assembly on the transmission telescopic stand. Remove the front and rear engine mounts.
32. Remove the engine and gearbox assembly without separating them from each other.
33, Remove the special tools from the vehicle.
Installation
1. Before installing the power unit (engine and gearbox), check the wiring, pipes, hoses, etc. Make sure that the specified parts are not damaged or pinched during installation.
2. Carefully install the front and rear engine mounts onto the bracket.
- Tightening torque: 50-65 Nm
3. Install the engine and gearbox assembly on the subframe. Using the transmission stand, carefully adjust the position of the power unit relative to the body and supports.
4. Install and tighten the transmission mount bolt to the support bracket.
- Tightening torque: 90-110 Nm
5. Install the side engine support.
Tightening torque:
- Bolt for fastening the support to the support bracket: 90-100 Nm
- Support mounting bolt: 50-65 Nm
6. Reinstall the remaining parts in the reverse order of removal.
7. Fill the cooling system and check for fluid leaks.
8. Fill the manual transmission with oil or the automatic transmission fluid and check for leaks. Check the correct operation of the transmission.
9. Check the operation of the gearbox control cable and the accelerator pedal cable.
10. Check the correct operation of the pointers and indicators.
11. Check for fuel leaks after connecting the fuel lines. Turn on the ignition for 2 seconds (do not turn on the starter) so that the fuel pump creates pressure in the fuel lines. Repeat this operation two or three times, then check for leaks at the connections.