Engine and Transaxle Assembly: Removal & Installation Hyundai Tucson II

Removal

Note. Mark all wiring and hoses to avoid misconnection. For release the fuel system pressure before remove the engine assembly, start the engine without fuel pump relay. And then turn off the ignition switch after engine stops.

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1. Disconnect the battery negative terminal (A). Tightening torque: (-) terminal: 4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
2. Remove the engine cover (B).
3. Remove the air duct (C).
4. Disconnect the breather hose (A), air intake hose (B) and then remove the air cleaner assembly (C). Tightening torque Hose clamp bolt: 2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft) Air cleaner assembly bolts: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
5. Disconnect the battery positive terminal and then remove the battery (D). Tightening torque: (+) terminal: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft) Bracket bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
6. Disconnect the ECM connector and then remove the ECM (A) and the battery tray (B). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
7. Remove the under cover (A). Tightening torque: 19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)
8. Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining. WARNING: Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.
9. Remove the radiator upper hose (A) and lower hose (B).
10. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe. (Refer to «AIR CONDITIONING SYSTEM»(ref-583680) .)
11. Disconnect the (+) cable (A) from the fuse box and the front connector (B).
12. Disconnect the wiring connectors, harness clamps from the engine. OCV connector (A) VIS connector (A) Oil pressure switch (B) Knock sensor connector (C) A/C compressor switch connector (D) Alternator connector (E) Injector connectors (A) Ignition coil connectors (B) Intake CMPS connector (C) Exhaust CMPS connector (D) Exhaust OCV connector (E) VCM connector (A) ETC connector (A) MAP & IATS connector (B) PCSV connector (A) ECT sensor connector (B) Condenser connector (C) CKP sensor connector (D) Oxygen sensor connector (E)
13. Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to «REMOVAL- Automatic Transaxle System»(ref-583681-S14677983612013102900000) or appropriate article in Manual Transaxle System).
14. Remove the front wheels. (Refer to «FRONT SUSPENSION SYSTEM»(ref-583682) .)
15. Remove the shock absorbers, refer to «FRONT SUSPENSION SYSTEM»(ref-583682) . Remove the stabilizer bar links and tie rod ends, refer to «STEERING GEAR BOX»(ref-583683-S21262936772013102900000) .)
16. Disconnect the drive shafts from the axle hub. (Refer to «DRIVESHAFT ASSEMBLY»(ref-583684) )
17. Remove the steering u-joint mounting bolt (A). (Refer to «STEERING GEAR BOX»(ref-583683-S21262936772013102900000) )
18. Disconnect the fuel hose (A), brake booster vacuum hose (B) and heater hoses (C).
19. Remove the front muffler (A). Tightening torque: 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
20. Remove the roll rod bracket (A). Tightening torque: 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
21. Remove the sub frame. (Refer to «FRONT SUSPENSION SYSTEM»(ref-583682) )
22. Support the engine and transaxle with a jack.
23. Disconnect the ground cable, and then remove the engine mounting bracket (A). Tightening torque: 78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
24. Disconnect the ground cable, and then remove the transaxle mounting bracket bolt (A). Tightening torque: 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
25. Remove the engine and transaxle assembly by lifting vehicle. CAUTION: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

Installation

Installation is in the reverse order of removal.

Perform the following

1. Adjust a shift cable.
2. Adjust a throttle cable.
3. Refill engine with engine oil.
4. Refill a transaxle with fluid.
5. Refill power steering fluid.
6. Refill a radiator and a reservoir tank with engine coolant.
7. Place a heater control knob on "HOT" position.
8. Clean battery posts and cable terminals and assemble.
9. Inspect for fuel leakage. After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
10. Bleed air from the cooling system. Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.) Turn Off the engine and let it cool down. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system. Put radiator cap on tightly, then run the engine again and check for leaks.