Removing and installing the G2.0–2.4DOHC engine

Let us consider the example of a Hyundai vehicle

Caution:

  • To avoid damaging the painted surfaces of the body, cover the front wings of the vehicle with protective covers.
  • Be careful when disconnecting hoses, do not spill oil or other fluid.
  • Plug the disconnected pipes or hoses to prevent foreign particles from entering.

Note: when disconnecting hoses, always apply installation marks beforehand so that, when reconnecting, the hoses are installed in their original position.

  • 1. Disconnect the cable from the negative terminal of the battery.
  • 2. Remove the decorative engine cover.
  • 3. Remove the air filter.
  • 4. (Models up to 2009.) Remove the intake air duct and the air filter housing.
    • a) Remove the mass air flow sensor.
    • b) Disconnect the breather hose from the air filter housing.
    • c) Disconnect the engine control unit connector.
    • d) Remove the intake air duct and the air filter housing (A). Tightening torque: 8–12 N·m.
Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 1. Power unit mounts: 1 — subframe; 2 — side engine mount bracket; 3 — front power unit mount bracket; 4 — automatic or manual transmission mount bracket; 5 — rear power unit mount bracket

5. (Models from 2009.) Remove the intake air duct and the air filter housing.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 2. Removing the air filter and intake air duct

a) Remove the intake air duct (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 3. Removing the intake air duct

b) Disconnect the breather hose (A), the engine control unit connector (B) and remove the air filter housing (C).
Tightening torque: 8–12 N·m.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 4. Removing the air filter

6. Remove the front wheels.
Tightening torque: 88.5–107.5 N·m.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 5. Removing the engine guard

7. Remove the lower engine guard (A).
Tightening torque: 8–12 N·m.

  • 8. Drain the coolant.
  • 9. Remove the radiator hoses (A).
Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 6. Removing the radiator hoses (models up to 2009)

Models up to 2009.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 7. Removing the radiator hoses (models from 2009)

Models from 2009.

10. Remove the heater hoses (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 8. Removing the heater hoses (models up to 2009)

Models up to 2009.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 9. Removing the heater hoses (models from 2009)

Models from 2009.

11. (Models up to 2009.) Disconnect the air conditioning compressor switch (A), the alternator connector (B) and the oil pressure warning sensor connector (C).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 10. Disconnecting connectors and switches (models up to 2009)

12. (Models from 2009.) Disconnect the solenoid valve connector of the intake manifold geometry change system (A), the oil pressure warning sensor connector (B), the knock sensor connector (C) and the air conditioning compressor connector (D).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 11. Disconnecting the connectors (models from 2009)

13. (Models up to 2009.) Disconnect the CVVT system valve (A) and oil temperature sensor (B) connectors.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 12. Disconnecting the connectors (models up to 2009)

14. (Models from 2009.) Disconnect the CVVT system valve connector (inlet valves) (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 13. Disconnecting the connectors (models from 2009)

15. (Models up to 2009.) Disconnect the injector connectors (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 14. Disconnecting the injector connectors (models up to 2009)

16. (Models from 2009.) Disconnect the injector connectors (A) and the ignition coil connectors (B).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 15. Disconnecting the coil and injector connectors (models from 2009)

17. (Models up to 2009.) Disconnect the throttle actuator connector (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 16. Disconnecting the throttle connector (models up to 2009)

18. (2.4 l, models from 2009.) Disconnect the throttle actuator connector (A) and the intake manifold absolute pressure sensor connector (B).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 17. Disconnecting the throttle and absolute pressure sensor connectors (2.4 l, models from 2009)

19. (2.0 l, models from 2009.) Disconnect the idle speed control valve connectors (A), the throttle position sensor (B), the intake manifold absolute pressure sensor (C) and the throttle cable (D).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 18. Disconnecting the connectors (2.0 l, models from 2009)

20. (Models up to 2009.) Disconnect the knock sensor (B) and camshaft position sensor (A) connectors.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 19. Disconnecting the sensors (models up to 2009)

21. (Models up to 2009.) Disconnect the ignition coil connectors (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 20. Disconnecting the ignition coils (models up to 2009)

22. (Models from 2009.) Disconnect the camshaft position sensor connector (A) and the fuel pipe (B).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 21. Disconnecting the connectors (models from 2009)

23. (Models up to 2009.) Disconnect the crankcase forced ventilation valve connector (A), the coolant temperature sensor connector (B), the capacitor connector (C), the crankshaft position sensor connector (D).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 22. Disconnecting the connectors (models up to 2009)

24. (Models up to 2009.) Remove the fuel rail (A), the brake servo vacuum hose (B) and the crankcase forced ventilation hose (C).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 23. Removing the rail and hoses (models up to 2009)

25. (Models from 2009.) Disconnect the crankcase forced ventilation valve connector (A), the coolant temperature sensor connector (B), the capacitor connector (C), the crankshaft position sensor connector (D), the camshaft position sensor connector (E) and the brake servo vacuum hose (F).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 24. Disconnecting the valve and sensors (models from 2009)

26. (Models from 2009.) Disconnect the connector (A) and the output “B” cable of the alternator (B).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 25. Disconnecting the alternator connectors (models from 2009)

27. (Models from 2009.) Disconnect the connector (A) and the cable (B) of the starter motor.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 26. Disconnecting the starter cables (models from 2009)

28. (Models up to 2009.) Disconnect the power steering fluid pressure sensor connector.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 27. Disconnecting the power steering sensor (models up to 2009)

29. (Models from 2009.) Disconnect the power steering fluid pressure sensor connector (A) and the CVVT system valve (exhaust valves) connector (B).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 28. Disconnecting the power steering sensor and valve connector (models from 2009)

30. Disconnect the power steering pump hose (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 29. Disconnecting the power steering hose

31. Remove the battery tray (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 30. Removing the battery tray

32. Disconnect the earth cable from the gearbox (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 31. Disconnecting the earth cable

33. (Models with automatic transmission.) Disconnect the following connectors:

  • starter inhibitor switch connector;
  • automatic transmission selector connector;
  • input shaft speed sensor connector;
  • output shaft speed sensor connector;
  • vehicle speed sensor connector;
  • selector position cable.
  • 34. Drain the automatic transmission fluid or manual transmission oil.
  • 35. Disconnect the EPS system solenoid valve connector.
Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 32. Disconnecting the solenoid valve
  • 36. Disconnect the lower suspension arms.
  • 37. Disconnect the track rod ends.
  • 38. Remove the anti-roll bar.
  • 39. Disconnect the drive shafts.
  • 40. Remove the clip (B), disconnect the return hose (A) and drain the power steering fluid.
Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 33. Disconnecting the hose

41. Disconnect the steering column universal joint.
Tightening torque (A): 18–24 N·m.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 34. Disconnecting the column joint

42. (Models up to 2009.) Disconnect the oxygen sensor connector (A).

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 35. Disconnecting the oxygen sensor (models up to 2009)
  • 43. (Models up to 2009.) Remove the front part of the exhaust downpipe.
  • 44. (Models from 2009.) Disconnect the oxygen sensor connector (A) and remove the front part of the exhaust downpipe (B).
Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 36. Disconnecting the oxygen sensor
  • 45. Install a support under the engine.
  • 46. Unscrew the bolts of the front and rear power unit mount brackets.
  • 47. Unscrew the subframe bracket bolts (B) and remove the subframe (A).
Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 37. Disconnecting the subframe
Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 38. Disconnecting the subframe

48. Remove the side engine mount bracket (A).
Tightening torque: 64–83 N·m.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 39. Removing the bracket

49. Remove the automatic or manual transmission mount bracket (A).
Tightening torque (B): 64–83 N·m.

Removal and installation of the G 2.0–2.4 DOHC engine
Fig. 40. Removing the bracket
  • 50. Lower the engine out of the engine compartment.
  • 51. Installation is carried out in the reverse order of removal.
  • 52. After installation, carry out the following operations:
    • a) Adjust the transmission control cables and the accelerator pedal cable.
    • b) Fill with engine oil, coolant, manual transmission oil or automatic transmission fluid (ATF).
    • c) Check the condition of the battery cables and terminals.
    • d) Check for fuel leaks after connecting the fuel lines. Turn on the ignition for 2 seconds (do not operate the starter) so that the fuel pump creates pressure in the fuel lines. Repeat this operation two or three times, then check for leaks at the connections.