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Home >> Hyundai >> 2018 >> Kona Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 115 (Engine And Transaxle Assembly (R & I) - 1.6L) >> Engine And Transaxle Assembly >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING: This page is about a different car, the 2021 Hyundai Kona. However, it is still accessible from the selected car via links, so may be relevant.
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.
  • To release the fuel system pressure before removing the engine assembly, start the engine with the fuel pump relay removed. And then turn off the ignition switch after engine stops.
  1. Disconnect the battery negative terminal.
  2. Remove the engine cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE COVER ")

  3. Remove the air duct and air cleaner assembly.

    (Refer to Intake and Exhaust System - "AIR CLEANER ")

  4. Remove the battery.

    (Refer to Engine Electrical System - "BATTERY ")

  5. Remove the engine control module (ECM).

    (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

  6. Remove the battery tray.

    (Refer to Engine Electrical System - "BATTERY ")

  7. Remove the engine room under cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE ROOM UNDER COVER ")

  8. Loosen the drain plug and drain the coolant and remove the radiator cap to speed draining.

    (Refer to Cooling System - "COOLANT ")

  9. Remove the intercooler inlet hose (A).

    Tightening Torque: 

    4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

    G12593018Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
    • The groove of hose must be in line with the protrusion of the pipe.
    • The band must be located on the position mark of hose and must not run over it.
    • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
  10. Disconnect the radiator upper hose (A).
    G12593019Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When installing radiator hoses, install as displayed in images.
    G12593020Courtesy of HYUNDAI MOTOR AMERICA
  11. Disconnect the radiator lower hose (A).
    G12593021Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When installing radiator hoses, install as displayed in images.
    G12593022Courtesy of HYUNDAI MOTOR AMERICA
  12. Remove the intercooler outlet hose and pipe.
    1. Disconnect the intercooler outlet hose (A).
    2. Disconnect the boost pressure sensor (BPS) connector (B).
    3. Disconnect the RCV solenoid hose (C).
    4. Disconnect the RCV solenoid connector (D).

      Tightening Torque: 

      4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

      G12593023Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
      • The marking of hose must be in line with the stopper of the throttle body.
      • The band must be located on the position mark of hose and must not run over it.
      • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
  13. Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).
    G12593024Courtesy of HYUNDAI MOTOR AMERICA
  14. Disconnect the reservoir tank water hose (A).
    G12593025Courtesy of HYUNDAI MOTOR AMERICA
  15. Disconnect the brake booster vacuum hose (A).
    G12593026Courtesy of HYUNDAI MOTOR AMERICA
  16. Disconnect the heater hoses (A).
    G12593027Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When installing heater hoses, install as displayed in images.
    G12593028Courtesy of HYUNDAI MOTOR AMERICA
  17. Disconnect the wiring harness from the engine room.
    1. Remove the ground bolt (A)
    2. Disconnect the battery negative terminal connector (B)
    3. Disconnect the front harness connector (C)
    4. Disconnect the PCB block (D)
    5. Disconnect the wiring protector (E)
      G12593029Courtesy of HYUNDAI MOTOR AMERICA
      G12593030Courtesy of HYUNDAI MOTOR AMERICA
    6. Disconnect the battery positive wirings (A)
    7. Disconnect the wiring protector (B)
      G12593031Courtesy of HYUNDAI MOTOR AMERICA
  18. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.

    (Refer to Heating, Ventilation Air conditioning - "COMPRESSOR ")

  19. Remove the transaxle wire harness connectors and control cable from the transaxle.

    (Refer to Dual Clutch Transmission (DCT) System - "DUAL CLUTCH TRANSMISSION CONTROL SYSTEM - 1.6L ")

  20. Remove the front muffler.

    (Refer to Intake and Exhaust System - "MUFFLER ")

  21. Remove the steering U-joint mounting bolt.

    (Refer to Steering System - "MDPS ASSEMBLY ")

  22. Remove the roll rod bracket (A).

    Tightening Torque 

    Bolt (B): 

    107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

    Bolts (C): 

    49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft)

    G12593032Courtesy of HYUNDAI MOTOR AMERICA
  23. Remove the roll rod mounting support bracket (A).

    Tightening Torque: 

    49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb-ft)

    G12593033Courtesy of HYUNDAI MOTOR AMERICA
  24. Remove the sub frame.

    (Refer to Suspension System - "SUB FRAME ")

  25. Support the sub frame with a floor jack.
  26. Disconnect the engine ground cable (A).

    Tightening Torque: 

    10.8 - 13.7 N.m (1.1 - 1.4 kgf.m, 8.0 - 10.1 lb-ft)

    G12593034Courtesy of HYUNDAI MOTOR AMERICA
  27. Disconnect the transaxle ground cable (A).

    Tightening Torque: 

    10.8 - 13.7 N.m (1.1 - 1.4 kgf.m, 8.0 - 10.1 lb-ft)

    G12593035Courtesy of HYUNDAI MOTOR AMERICA
  28. Remove the engine mounting support bracket (A).

    Tightening Torque 

    Nut (B): 

    78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

    Bolt (C), Nuts (D): 

    58.8 - 73.5 N.m (6.0 - 7.5 kgf.m, 43.4 - 54.2 lb-ft)

    G12593036Courtesy of HYUNDAI MOTOR AMERICA
  29. Remove the service cover (A).
    G12593037Courtesy of HYUNDAI MOTOR AMERICA
  30. Remove the transaxle support bracket mounting bolts (A).

    Tightening Torque: 

    107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

    G12593038Courtesy of HYUNDAI MOTOR AMERICA
  31. Remove the engine and transaxle assembly by lifting vehicle.
    G12593039Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • Before removing the engine and transaxle assembly, make sure hoses and wire connectors are disconnected.
    • When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
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