Hyundai Tucson LM Quiz
Engine Mechanical System

Engine and Transaxle Assembly Repair Procedures

In this manual: Engine Mechanical System
General Information — 1Engine Mechanical System — 44Engine Electrical System — 45Emission Control System — 24Engine Control System/Fuel System — 93Clutch System — 13Manual Transmission — 18Automatic Transmission — 87Four-Wheel Drive (4WD) System — 26Drive Shaft and Axle — 29Suspension System — 35Steering — 20Restraints — 47Brake System — 36Body (Interior and Exterior) — 53Body Electrical System — 202Heating, Ventilation, and Air Conditioning — 58
31steps
~186min
4/5difficulty
010203040509.87N·mlb·ft
Tightening torque found on this page
Done 0 of 31

Removal
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, carefully disconnect the wiring connectors by holding the connector body.
  • Label all wires and hoses to avoid incorrect connection.
  • To release fuel pressure before removing the engine assembly, start the engine with the fuel pump relay removed. Then turn the ignition off after the engine stops.
  1. Remove the engine cover (A).
    • To prevent damage, remove the engine cover at room temperature.
    • To prevent damage to the engine cover, do not disconnect the front and rear mounting points at the same time.
  2. Disconnect the battery terminals (A). Disconnect the negative terminal first. Tightening torque: (+) terminal: 7.8 ~ 9.8 N·m; (-) terminal: 3.9 ~ 5.9 N·m
  3. Remove the air cleaner assembly.
    1. Remove the air duct (B).

      Tightening torque: 7.8 ~ 9.8 N·m

    2. Disconnect the breather hose (C).
    3. Disconnect the air intake hose (D) and remove the air cleaner assembly (E). Tightening torque: Hose clamp bolt: 2.9 ~ 4.9 N·m; Air cleaner mounting bolts: 7.8 ~ 9.8 N·m
    • Install the air intake hose so that the clamp plate is aligned with the hose plug.
    • Install the air intake hose so that the center of the hose mark is aligned with the throttle body rib.
  4. Remove the battery (A) after removing the battery mounting bracket (B).

    Tightening torque: 9.8 ~ 14.7 N·m

  5. Disconnect the ECM connectors (A) and remove the ECM (B).

    Tightening torque: 9.8 ~ 11.8 N·m

  6. Loosen the battery "+" cable bracket mounting bolt (A) and remove the battery tray (B).

    Tightening torque: 9.8 ~ 14.7 N·m

  7. Remove the lower cover (A).

    Tightening torque: 7.8 ~ 11.8 N·m

  8. Loosen the drain plug and drain the engine coolant. Remove the radiator cap to drain the coolant faster. (Refer to Cooling System in this group)
  9. Disconnect the upper radiator hose (A).
  10. Disconnect the radiator lower hose (A).
  11. Recover the refrigerant, then remove the high pressure line and low pressure line (A). (Refer to Heating, Ventilation and Air Conditioning - Air Conditioning System)
  12. Disconnect the transaxle wiring harness connectors, control cable and hoses from the transaxle. (Refer to Manual Transmission System) (Refer to Automatic Transmission section)
  13. Disconnect the heater hoses (A).
    When installing the heater hoses, install them as shown in the illustrations.
  14. Disconnect the wiring connectors and harness clips, then remove the wiring and protector from the cylinder head and intake manifold.
    1. OCV (Oil Control Valve) Intake Connector (A)
    2. OCV (Oil Control Valve) Exhaust Connector (A)
    3. Alternator Connector (A)
    4. Ignition Coil Connectors (A), Fuel Pump Connector (B).
    5. CMPS (Camshaft Position Sensor) Intake Connector (A)
    6. CMPS (Camshaft Position Sensor) Exhaust Connector (B)
    7. Injector Connectors (A)
    8. Front and/or Rear Heated Oxygen Sensor (HO2S) Connectors (A)
    9. Condenser Connector (A)
    10. PCSV (Purge Control Solenoid Valve) Connector (A)
    11. ECTS (Engine Coolant Temperature Sensor) Connector (A)
    12. VIS (Variable Intake System) Connector (A)
    13. MAPS (Manifold Absolute Pressure Sensor) and IATS (Intake Air Temperature Sensor) Connector (A)
    14. ETC (Electronic Throttle Control) Connector (A)
  15. Disconnect the "+" cable (A) and front connector (B).
  16. Disconnect the fuel hose (A) and PCSV (Purge Control Solenoid Valve) hose (B).
  17. Remove the front muffler (A).

    Tightening torque: 39.2 ~ 59 N·m

  18. Remove the steering universal joint mounting bolt (A). (Refer to Steering System - Steering Gear Box)
  19. Remove the front wheels. (Refer to Suspension System)
  20. Remove the lower arms (A). (Refer to Suspension System - Front Lower Arm)
  21. Remove the stabilizer bar links (A). (Refer to Suspension System - Front Stabilizer Bar)
  22. Remove the tie rod ends (A). (Refer to Steering System - Steering Gear Box)
  23. Disconnect the drive shafts (A) from the hub assemblies. (Refer to Drive Shaft and Axle - Front Drive Shaft)
  24. Remove the roller rod bracket (A). Tightening torque: Nut (B): 107.9 ~ 128 N·m; Bolt (C): 49.0 ~ 64 N·m
  25. Remove the roller rod bracket (A).

    Tightening torque: 49.0 ~ 69 N·m

  26. Support the subframe (A) with a jack, then remove the subframe mounting bolts and nuts. Tightening torque: Subframe mounting bolts and nuts: 176.5 ~ 197 N·m (18.0 ~ 20.0 kgf·m, 130.2 ~ 144.7 ft-lbf)
    • After removing the subframe mounting bolts and nuts, the engine and transaxle assembly may drop. Support it securely with a floor jack.
    • Before removing the engine and transaxle assembly, make sure all hoses and connectors are disconnected.
  27. Disconnect the ground line (A), then remove the engine mounting bracket (B). Tightening torque: Ground line bolt (A): 10.8 ~ 13.7 N·m; Nut (C): 78.5 ~ 98 N·m; Bolt (D) and nuts (E): 78.5 ~ 98 N·m
  28. Disconnect the ground line (A).
  29. Remove the service cover (A).
  30. Remove the transaxle mounting bracket bolt (A).

    Tightening torque: 88.3 ~ 108 N·m

  31. Lower the engine and transaxle assembly (A) using a floor jack, then remove the engine and transaxle assembly by raising the vehicle.
    When removing the engine and transaxle assembly, be careful not to damage surrounding parts or body components.

Installation

Installation is the reverse of removal.
Perform the following procedure:
  • Adjust the shift cable.
  • Fill the engine with engine oil.
  • Fill the transmission with fluid.
  • Fill the radiator and the coolant reservoir with engine coolant.
  • Clean the battery terminal posts and cable clamps, then assemble.
  • Inspect for fuel leaks.
  • After assembling the fuel line, turn the ignition ON (do not crank the engine) so the fuel pump operates for approximately two seconds to pressurize the fuel line.
  • Repeat this procedure two or three times, then check all fuel line connections for leaks.
  • Bleed air from the cooling system.
  • Start the engine and let it run until warm (until the radiator fan cycles 3 or 4 times).
  • Turn the engine off. Check the coolant level in the radiator and add coolant if necessary. This allows trapped air to be removed from the cooling system.
  • Tightly close the radiator cap, then restart the engine and check for leaks.

Test yourself

A quick Hyundai Tucson LM quiz: every answer comes with an explanation and a link to the manual page.