Repair Procedures: Removal

CAUTION:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:

Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

Disconnect the negative terminal from the battery.
Remove the air duct (A).

Fig 1: Identifying Air Duct

G06801397

Courtesy of HYUNDAI MOTOR CO.

Remove the intake air hose and air cleaner assembly.
1. Disconnect the breather hose (A).
2. Disconnect the ECM connectors (B).
3. Disconnect the AFS connector (C) and then remove the air cleaner assembly (D).

Fig 2: Identifying AFS Connector, Breather Hose, Intake Air Hose And Air Cleaner

G00510024

Courtesy of HYUNDAI MOTOR CO.

Remove the under cover(A).

Fig 3: Identifying Under Cover

G06801399

Courtesy of HYUNDAI MOTOR CO.

Remove the RH front wheel and the side cover (A).

Fig 4: Identifying RH Front Wheel Side Cover
Courtesy of HYUNDAI MOTOR CO.
Drain the engine coolant.
Remove the radiator cap to speed draining.
Remove the upper radiator hose(A).

Fig 5: Identifying Upper Radiator Hose
Courtesy of HYUNDAI MOTOR CO.
Drain the engine oil.
Remove the lower oil pan(A).
Insert the blade of SST(09215-3C000) between the upper oil pan and lower oil pan, and cut off applied sealer and removed lower oil pan.

Fig 6: Removing Lower Oil Pan
Courtesy of HYUNDAI MOTOR CO.
NOTE:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
- After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not use the SST as a prybar. Hold the tool in position (on the gasket line) and tap in with a light hammer.
- Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
Install the jack to the upper oil pan.

Fig 7: Locating Upper Oil Pan
Courtesy of HYUNDAI MOTOR CO.

NOTE: Place a rubber block between oil pan and jack.
Just loosen the transaxle mounting bolts (A) without removing the transaxle mounting (B).

Fig 8: Identifying Transaxle Mounting With Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove the engine coolant reservoir tank (A).
Disconnect the ground cable (B) and then remove the engine mounting support bracket (C).

Fig 9: Identifying Engine Coolant Reservoir Tank And Engine Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
Loosen the A/C pipe bracket mounting bolt (A).

Fig 10: Identifying A/C Pipe Bracket Mounting Bolt
Courtesy of HYUNDAI MOTOR CO.
Remove the engine mounting bracket (A) through the lower position of A/C pipe line.

Fig 11: Identifying No. 1 Engine Mounting
Courtesy of HYUNDAI MOTOR CO.
Disconnect the wiring connectors and then remove the surge tank. (Refer to INTAKE SYSTEM AND EXHAUST SYSTEM

Fig 12: Identifying Surge Tank
Courtesy of HYUNDAI MOTOR CO.

NOTE: Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
Disconnect the RH ignition coil connectors (A) and the injector connectors (B).

Fig 13: Identifying RH Ignition Coil Connector (A) And Injector Connectors (B)
Courtesy of HYUNDAI MOTOR CO.
Remove the LH, RH ignition coil.
Remove the exhaust OCV cap (A), and then remove the LH, RH cylinder head covers.

Fig 14: Locating The Exhaust OCV Cap (A), And The LH, RH Cylinder Head Covers
Courtesy of HYUNDAI MOTOR CO.

NOTE: Cover the cylinder head with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
To release the tension, turn the drive belt tensioner counterclockwise then remove the drive belt (A).

Fig 15: Engine Drive Belt Routing
Courtesy of HYUNDAI MOTOR CO.
Lift up the engine assembly by using the jack for get a space to work.
Remove the power steering pump(A).

Fig 16: Identifying Power Steering Pump

G06801433

Courtesy of HYUNDAI MOTOR CO.

Remove the air conditioner compressor(A).

Fig 17: Identifying Air Conditioner Compressor

G06801434

Courtesy of HYUNDAI MOTOR CO.

Remove the alternator(A).

Fig 18: Identifying Alternator

G06801435

Courtesy of HYUNDAI MOTOR CO.

Remove the drive belt idler(A).

Fig 19: Identifying Drive Belt Idler

G06801436

Courtesy of HYUNDAI MOTOR CO.

Remove the drive belt auto tensioner(A).

Fig 20: Identifying Drive Belt Auto Tensioner With Bolts

G06801437

Courtesy of HYUNDAI MOTOR CO.

Remove water pump pulley(A).

Fig 21: Identifying Water Pump Pulley

G06801438

Courtesy of HYUNDAI MOTOR CO.

Set No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley and align its groove with the timing mark "T" of the timing chain cover.
  NOTE: Do not rotate engine counterclockwise.
  
  Fig 22: Identifying Timing Mark "T" Of Lower Timing Chain Cover
  Courtesy of HYUNDAI MOTOR CO.
2. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°).
  
  Fig 23: Identifying Timing Marks (A) on LH Camshafts
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 24: Identifying Timing Marks (A) on RH Camshafts
  Courtesy of HYUNDAI MOTOR CO.
  
  NOTE: Do not rotate engine counterclockwise.
Remove the crankshaft pulley(A).

Fig 25: Identifying Crankshaft Damper Pulley
Courtesy of HYUNDAI MOTOR CO.
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (flywheel stopper, 09231-3C300) to hold the ring gear after removing the starter.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
  1. Remove the front muffler. (Refer to MUFFLER
  2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
  3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
  4. Fasten the two transaxle mounting bolts in the original mounted holes.
  5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
Remove the timing chain cover(A).

Fig 30: Identifying Tinning Chain Cover (A)
Courtesy of HYUNDAI MOTOR CO.
CAUTION:
- Disconnect the water vent hose located at back of timing chain cover before removing.
- Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
NOTE:
- Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
Fig 31: Identifying Timing Mark On LH Camshafts
Courtesy of HYUNDAI MOTOR CO.

Fig 32: Identifying Timing Mark On Sprockets
Courtesy of HYUNDAI MOTOR CO.

Fig 33: Identifying Timing Mark On RH Camshafts
Courtesy of HYUNDAI MOTOR CO.

Fig 34: Identifying Timing Mark On Crankshaft Sprockets
Courtesy of HYUNDAI MOTOR CO.

Fig 35: Locating Oil Pump Chain Cover(A)
Courtesy of HYUNDAI MOTOR CO.

Fig 36: Locating Oil Pump Chain Tensioner Assembly(A)
Courtesy of HYUNDAI MOTOR CO.

Fig 37: Locating RH Timing Chain Guide(A)
Courtesy of HYUNDAI MOTOR CO.

Fig 38: Identifying Pin Compressing Timing Chain Tensioner
Courtesy of HYUNDAI MOTOR CO.

Fig 39: Identifying RH Timing Chain Auto Tensioner And RH Timing Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR CO.

Fig 40: Identifying RH Timing Chain Guide (A) And RH Timing Chain (B)
Courtesy of HYUNDAI MOTOR CO.

Fig 41: Identifying Oil Pump Chain Sprocket And Oil Pump Chain
Courtesy of HYUNDAI MOTOR CO.

Fig 42: Locating Crankshaft Sprocket(A) (Oil Pump & RH Camshaft Drive)
Courtesy of HYUNDAI MOTOR CO.

Fig 43: Installing Set Pin After Compressing LH Timing Chain Tensioner
Courtesy of HYUNDAI MOTOR CO.

Fig 44: Identifying RH Timing Chain Auto Tensioner (A) And The RH Timing Chain Tensioner Arm(B)
Courtesy of HYUNDAI MOTOR CO.

Fig 45: Identifying LH Timing Chain Guide (A) And LH Timing Chain (B)
Courtesy of HYUNDAI MOTOR CO.

Fig 46: Locating RH Timing Chain Guide(A)
Courtesy of HYUNDAI MOTOR CO.

Fig 47: Locating Crankshaft Sprocket(A) (Oil Pump & RH Camshaft Drive)
Courtesy of HYUNDAI MOTOR CO.

Fig 48: Identifying LH Timing Chain Guide (A) And LH Timing Chain (B)
Courtesy of HYUNDAI MOTOR CO.

Fig 49: Identifying Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.

Fig 50: Locating Tensioner Adapter Assembly(A)
Courtesy of HYUNDAI MOTOR CO.