Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.

Engine removal is not required for this procedure.

CAUTION:

Use fender covers to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE: Mark all wiring and hoses to avoid mis-connection.

Remove the engine cover.
Disconnect the battery negative terminal.
Remove the air duct and air cleaner assembly.
(Refer to Intake and Exhaust System - "AIR CLEANER ")
Disconnect the mounting bracket and then remove the battery.
(Refer to Engine Electrical System - "BATTERY ")
Disconnect the ECM connector and then remove the battery tray.
(Refer to Engine Electrical System - "BATTERY ")
Remove the battery tray.
(Refer to Engine Electrical System - "BATTERY ")
Remove the engine room under cover.
Loosen the drain plug and drain the coolant. Open the radiator cap to make rapid draining.
(Refer to Cooling System - "COOLANT ")
Remove the radiator upper hose and lower hose.
(Refer to Cooling System - Radiator Hose - "Radiator ")
Disconnect the intercooler inlet and outlet hose.
(Refer to Intake and Exhaust System - Intercooler Pipe and Hose - "Intercooler ")
Disconnect the engine wiring connector and harness clamp and then remove the cylinder head protector and wiring from engine.

Fig 1: Engine Wiring Connector And Harness Clamp (1 Of 3)
Courtesy of HYUNDAI MOTOR AMERICA

Fig 2: Engine Wiring Connector And Harness Clamp (2 Of 3)
Courtesy of HYUNDAI MOTOR AMERICA

Fig 3: Engine Wiring Connector And Harness Clamp (3 Of 3)
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the brake booster vacuum hose (A).

Fig 4: Locating Brake Booster Vacuum Hose
Courtesy of HYUNDAI MOTOR AMERICA
Remove the heater hose (A).

Fig 5: Locating Heater Hose
Courtesy of HYUNDAI MOTOR AMERICA
Remove the vacuum pipe assembly (A).

Fig 6: Locating Vacuum Pipe Assembly With Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")
Remove the timing chain cover.
(Refer to Timing System - "TIMING CHAIN COVER ")
Remove the timing chain.
(Refer to Timing System - "TIMING CHAIN ")
Remove the camshaft.
(Refer to Cylinder Head Assembly - "CAMSHAFT ")
Remove the intake manifold.
(Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")
Remove the turbo manifold.
(Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")
Remove the delivery pipe assembly.
(Refer to Fuel System - "DELIVERY PIPE ")
Disconnect the bypass hose, and then remove the water temperature control assembly.
(Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")
Remove the heater pipe.
(Refer to Cooling System - "WATER PIPE ")
Remove the intake OCV (Oil Control Valve).
(Refer to Fuel System - "CVVT OIL CONTROL VALVE ")
Remove the rear hanger (A).

Fig 7: Locating Rear Hanger
Courtesy of HYUNDAI MOTOR AMERICA
Remove the cylinder head cover heat protector (A).

Fig 8: Locating Cylinder Head Cover Heat Protector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the cylinder head bolts, then remove the cylinder head.
1. Uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.
  
  Fig 9: Cylinder Head Bolts Loosening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order.
2. Lift the cylinder head from the cylinder block and put the cylinder head on wooden blocks.
  CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.