Engine and Transaxle Assembly - Turbo: Removal & Installation Hyundai Veloster I

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. Remove the engine cover.
2. Disconnect the battery negative terminal.
3. Remove the air duct and air cleaner assembly. (Refer to " «AIR CLEANER»(ref-609292-S06516152692014041600000) ")
4. Disconnect the mounting bracket and then remove the battery. (Refer to " «BATTERY»(ref-609293-S32339350752014041600000) ")
5. Disconnect the ECM connector and then remove the battery tray. (Refer to " «BATTERY»(ref-609293-S32339350752014041600000) ")
6. Remove the battery tray. (Refer to " «BATTERY»(ref-609293-S32339350752014041600000) ")
7. Remove the engine room under cover.
8. Loosen the drain plug and drain the coolant. Open the radiator cap to make rapid draining. (Refer to " «COOLANT»(ref-609294-S25286250992014041600000) ")
9. Remove the radiator upper hose and lower hose. (Refer to " «RADIATOR HOSE»(ref-609294-S27516986072014041600000) ")
10. Remove the intercooler inlet and outlet hose. (Refer to " «INTERCOOLER PIPE & HOSE»(ref-609292-S23241155872014041600000) ")
11. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe. (Refer to " «Repair Procedures»(ref-609295-S13903129002014041600000) ")
12. Disconnect the wiring connector and cable from transaxle. (Refer to " «AUTOMATIC TRANSAXLE»(ref-609296-S33689888732014041600000) ")
13. Remove the ATF cooler hose. (Refer to " «AUTOMATIC TRANSAXLE»(ref-609296-S33689888732014041600000) ")
14. Remove the heater hose (A) and booster vacuum hose (B).
15. Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) (B).
16. Disconnect the ground cable (A).
17. Disconnect the engine wiring connector and harness clamp and then remove the cylinder head protector and wiring from engine. Turbo charger solenoid valve connector Exhaust OCV (Oil Control Valve) connector Ignition connector # 1, 2, 3, 4 FPCV (Fuel Pressure Control Valve) connector Condenser connector Exhaust CMPS (Cam position Sensor) connector Intake CMPS (Cam Position Sensor) connector Injector Extension connector PCSV (Purge Control Solenoid Valve) connector Intake OCV (Oil Control Valve) connector Alternator connector A/C compressor switch connector MAPS (Map Sensor) connector Knock Sensor connector Front connector CKPS (Crank Shaft Position Sensor) connector vacuum Pump Extension connector ETC (Electric Throttle Control) Module connector WTS (Water Temperature Sensor) connector Ground Cable Front Oxygen Sensor connector Rear Oxygen Sensor connector
18. Disconnect the (+) cable (A) from fuse box. Tightening torque Nut (A): 6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
19. Remove the catalytic convertor. (Refer to «INTAKE SYSTEM & EXHAUST SYSTEM - TURBO»(ref-609292) )
20. Remove the steering U-joint bolt. (Refer to " «STEERING GEAR BOX»(ref-609297-S08347513932014041600000) ")
21. Remove the front tire.
22. Remove the lower arms. (Refer to " «FRONT LOWER ARM»(ref-609298-S35603643272014041600000) ")
23. Remove the stabilizer links with the front strut assembly after loosening the nut. (Refer to " «STEERING GEAR BOX»(ref-609297-S08347513932014041600000) ")
24. Loosen the nut and then remove the tie-rod end with the front axle. (Refer to " «STEERING GEAR BOX»(ref-609297-S08347513932014041600000) ")
25. Remove the drive shaft assembly. (Refer to " «FRONT DRIVESHAFT»(ref-609299-S10276720662014041600000) ")
26. Remove the roll rod bracket. (Refer to " «ENGINE MOUNTING»(ref-609291-S12300185262014041600000) ")
27. Remove the roll rod support bracket. (Refer to " «ENGINE MOUNTING»(ref-609291-S12300185262014041600000) ")
28. Support the sub frame with a floor jack and then remove the sub frame mounting bolts and nuts. (Refer to " «SUB FRAME»(ref-609298-S30069688252014041600000) ") NOTE: After removing the engine and transaxle mounting bolts and nuts, the engine and transaxle assembly may fall downward. Support them securely with floor jack. Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
29. Using a floor jack, support the engine and transaxle assembly.
30. Disconnect the ground cable, and then remove the engine support mounting bracket. Refer to «Engine Mounting»(ref-609291-S12300185262014041600000)
31. Disconnect the ground (A), and then remove the transmission mounting bracket bolts. (Refer to " «AUTOMATIC TRANSAXLE»(ref-609296-S33689888732014041600000) ")
32. Remove the engine and transaxle assembly (A) in the forward direction from the 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 the shift cable.
2. Adjust the 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. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.