Hyundai i20 Quiz
Engine Mechanical System

ENGINE AND TRANSAXLE Repair Procedures

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
31steps
~186min
4/5difficulty
010203040506.95N·mlb·ft
Tightening torque found on this page
Done 0 of 31

DEPOSIT

  1. Disconnect the negative battery cable.
  2. Remove the engine cover. (Refer to Engine and Transaxle - "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 Fuel System/Engine Control - "Engine Control Module (ECM)")
  6. Remove the battery tray. (Refer to Engine Electrical System - "Battery")
  7. Remove the engine undercover. (Refer to Engine and Transaxle Assembly - "Engine Undercover")
  8. Drain the engine coolant. (Refer to Cooling System - "Coolant")
  9. Recover the refrigerant, then disconnect the high-pressure and low-pressure hoses. (Refer to Heating, Ventilation and Air Conditioning - "Compressor")
  10. Disconnect the transmission wiring harness connectors and the transmission control cable. (Refer to Manual Transmission System - "Manual Transmission")
  11. Remove the intercooler inlet pipe and hoses (B). Tightening torque: Hose clamp bolt: 4.9 ~ 6.9 N·m (If equipped with a cap, tighten until the cap is separated.) Pipe mounting bolt: 19.6 ~ 26 N·m
  12. Disconnect the heat exchanger outlet hose (A) and the radiator upper hose (B). Tightening torque: 4.9 ~ 6.9 N·m (If equipped with a cap, tighten until the cap is separated.)
  13. Disconnect the radiator lower hose (A).
  14. Disconnect the coolant hose from the reserve tank (A) and the coolant pipe hose (B).
  15. Disconnect the brake booster vacuum hose (A).
  16. Disconnect the hoses (A) from the heater.
  17. Disconnect the fuel hose (A), the pressure control solenoid valve (PCSV) hose (B), and the RCV solenoid valve hose (C).
  18. Disconnect the fuse box cable (A), the front connector (B), and the transmission ground cable (C).
  19. Disconnect the battery negative terminal (A), the EMS unit (B), the fuse box connector (C), and the ground cable (D).
  20. Remove the front muffler. (Refer to Intake and Exhaust System - "Muffler")
  21. Remove the steering universal joint mounting bolt. (Refer to Steering Systems Group - Column and Shaft)
  22. Remove the idler arm bracket (A). Tightening torque: Bolt (B): 107.9 ~ 128 N·m Bolts (C): 49.0 ~ 64 N·m
  23. Remove the roller rod mounting bracket (A).

    Tightening torque: 49.0 ~ 69 N·m

  24. Remove the subframe. (Refer to Suspension System - "Subframe")
  25. Support the engine and transmission with a floor jack.
  26. Disconnect the engine ground cable (A).

    Tightening torque: 10.8 ~ 13.7 N·m

  27. Remove the engine mounting bracket (A). Tightening torque: Nut (B): 88.2 - 108 N·m Bolt (C) and nut (D): 58.8 - 74 N·m
  28. Disconnect the transmission ground cable (A).

    Tightening torque: 10.8 ~ 13.7 N·m

  29. Remove the cover (A).
  30. Remove the transmission mounting bolts (A).

    Tightening torque: 88.2 - 108 N·m

  31. Remove the engine and transmission assembly (A) by raising the vehicle.

REMEDY

To install, reverse the removal procedure. Perform the following steps:
  • Adjust the shift cable.
  • Fill the engine with engine oil.
  • Fill the gear oil into the transaxle.
  • Fill the power steering system with fluid.
  • Fill the radiator and reserve tank with engine coolant.
  • Turn the heater control knob to the "HOT" position.
  • Clean the battery terminals and cable terminals, then reconnect them.
  • Check for fuel leaks.
  • After installing the fuel line, turn the ignition ON (do not crank the engine) so the fuel pump operates for about two seconds and the fuel line is pressurized.
  • Repeat this procedure two or three times and check that there are no fuel leaks in the fuel line.
  • Bleed air from the cooling system.
  • Start the engine and let it run until warm (until the radiator fan has operated 3 or 4 times).
  • Turn the engine off. Check the coolant level in the radiator and add coolant if necessary. This releases air trapped in the cooling system.
  • Slightly loosen the radiator cap and restart the engine. Run the engine and check for leaks.

Test yourself

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