Hyundai Kona: Engine and Transaxle Assembly / Engine and Transaxle Assembly Repair procedures

Hyundai Kona (OS) 2018-2024 Service Manual / Engine Mechanical System / Engine and Transaxle Assembly / Engine and Transaxle Assembly Repair procedures

Removal

•	Use fender covers to avoid damaging painted surfaces.

•	To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

•	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")

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)

•	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).

•	When installing radiator hoses, install as shown in illustrations.

11.

Disconnect the radiator lower hose (A).

•	When installing radiator hoses, install as shown in illustrations.

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)

•	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).

14.	Disconnect the reservoir tank water hose (A).

15.	Disconnect the brake booster vacuum hose (A).

16.

Disconnect the heater hoses (A).

•	When installing heater hoses, install as shown in illustrations.

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)

(6)	Disconnect the battery positive wirings (A)

(7)	Disconnect the wiring protector (B)

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 Control System")

20.	Remove the front muffler. (Refer to Intake and Exhaust System - "Muffler")

21.	Remove the steering U-joint mounting bolt. (Refer to Steering System - "Steering Column and Shaft")

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)

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)

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)

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)

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)

29.	Remove the service cover (A).

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)

31.

Remove the engine and transaxle assembly by lifting vehicle.

•	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.

Installation

Installation is in the reverse order of removal.

Perform the following :

•	Adjust a shift cable.

•	Refill engine with engine oil.

•	Refill a transaxle with fluid.

•	Refill a radiator and a reservoir tank with engine coolant.

•	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.

•	Place a heater control knob on "HOT" position.

•	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.

•	Clean battery posts and cable terminals and assemble.

Engine Mounting Repair procedures

Removal and Installation Roll rod bracket 1. Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover&qu ...

Timing System

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