Complete removal and reinstallation of the 2.5L I4 engine from a 2016-2024 Hyundai Tucson AWD, including disconnection of all engine accessories, mounts, drivetrain components, and fluids.

Warnings

Tools required

Parts

• Engine oil and filter × 1 — Use OEM specification
• Engine coolant × 1 — Hyundai/Kia Long Life Green
• Oil drain plug crush washer × 1 — Use OEM specification
• Exhaust manifold gasket set × 1 — Use OEM specification
• Transmission-to-engine gasket or seal × 1 — Use OEM specification
• Engine mount hardware (if reusing mounts) × 1 — Inspect and replace as needed
• Coolant hoses (if deteriorated) × 1 — Inspect upper and lower radiator hoses
• Accessory drive belt × 1 — Use OEM specification
• Flywheel bolts if TTY × 1 — Verify TTY requirement in service manual

Fluids

• Hyundai Genuine 0W-20 Engine Oil — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 10 qt
• Hyundai SP-IV-M ATF — 10 qt
• 75W-90 GL-5 Gear Oil (Front Differential) — 1.5 qt
• 75W-90 GL-5 Gear Oil (Rear Differential) — 2 qt
• Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable, then positive cable, and remove battery from vehicle
3. Drain engine coolant completely into appropriate container by opening radiator drain and lower hose
4. Drain engine oil and remove oil filter
5. Remove engine cover and plastic trim panels from top of engine bay
6. Raise vehicle on lift or secure on jack stands at proper lift points
7. Remove front wheels and engine splash shields
8. Drain transmission fluid and transfer case fluid if replacement engine requires transmission removal
9. Remove front bumper cover for improved access to radiator and cooling system
10. Take photos of all electrical connectors, vacuum lines, and hose routing for reference during reassembly

Procedure

1. 1

   Relieve fuel system pressure and disconnect fuel lines
   Remove fuel pump relay from fuse box and start engine, allowing it to run until it stalls. Attempt to restart several times until engine will no longer fire. Disconnect fuel supply and return lines at fuel rail using proper fuel line disconnect tools. Cap open lines to prevent contamination.
   ⚠️Fuel will spray under pressure if system is not properly relieved. Work in well-ventilated area away from ignition sources.
2. 2

   Remove intake system and air cleaner assembly
   Disconnect mass airflow sensor electrical connector. Loosen clamps and remove air intake duct from throttle body to air filter housing. Remove complete air cleaner assembly including housing and mounting brackets. Disconnect PCV hoses and vacuum lines from intake manifold, labeling each for correct reinstallation.
3. 3

   Disconnect cooling system components
   Remove upper and lower radiator hoses from engine. Disconnect heater hoses at firewall connections. If equipped with engine oil cooler, disconnect oil cooler lines. Remove radiator cooling fan assembly (typically 4 bolts). On AWD models, disconnect transmission cooler lines from radiator. Remove radiator assembly completely for clearance.
4. 4

   Remove accessory drive belt and disconnect accessories
   Using serpentine belt routing diagram on radiator support, release tension and remove accessory drive belt. Disconnect electrical connectors from alternator, A/C compressor clutch, and any other belt-driven accessories. Remove A/C compressor mounting bolts and secure compressor to frame with wire or zip ties without disconnecting refrigerant lines. Remove alternator mounting bolts and set alternator aside. Remove power steering pump mounting bolts if equipped with hydraulic pump (most 2.5L use electric steering) and secure without disconnecting lines.
   Torque spec

   AC Compressor Bolts25 Nm (18 lb-ft)

   Alternator Mounting Bolts50 Nm (37 lb-ft)

   Power Steering Pump Bolts25 Nm (18 lb-ft)
5. 5

   Disconnect engine wiring harness and control modules
   Disconnect all engine harness connectors including: throttle position sensor, fuel injector connectors, ignition coil connectors, camshaft and crankshaft position sensors, oxygen sensors (front and rear), knock sensors, oil pressure sensor, and coolant temperature sensors. Release wiring harness from all retaining clips along engine. Disconnect main engine control module (ECM) connector if ECM is mounted on engine. Unbolt any ground straps from engine block to chassis.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
6. 6

   Disconnect exhaust system
   Spray exhaust manifold nuts and studs with penetrating oil. From underneath vehicle, support front exhaust pipe with jack or wire. Remove exhaust manifold-to-front pipe connection nuts (typically spring-loaded flange connection). Lower exhaust system and secure out of way. If manifold needs removal, remove exhaust manifold nuts working from hot (center) to cold (outer) pattern to prevent warping.
   ⚠Exhaust studs are prone to breaking on higher-mileage vehicles. Apply penetrating oil and allow to soak before removal.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
7. 7

   Disconnect drivetrain components for AWD
   Mark alignment of front driveshaft to transfer case and front differential with paint or punch marks. Remove front driveshaft bolts and remove driveshaft. Support front differential with transmission jack. Remove front differential mounting bolts and lower differential assembly. Disconnect driver and passenger side axle shafts from transfer case by removing axle retaining clips or bolts. Support axles and secure to suspension to prevent damage to CV boots.
   ⚠Driveshaft must be reinstalled in original orientation to prevent driveline vibration. Mark clearly before removal.
8. 8

   Separate transmission from engine (partial separation)
   Position transmission jack under transmission for support. Disconnect transmission electrical connectors and shift cable linkage. Remove starter motor mounting bolts and remove starter. Remove lower transmission-to-engine bolts while ensuring transmission is properly supported. Remove upper transmission bell housing bolts. Carefully separate transmission back approximately 2-3 inches to clear torque converter or clutch assembly from crankshaft, but keep transmission supported and attached to engine via hoist for combined removal.
   ⚠Transmission must remain supported at all times. Do not allow transmission to hang by input shaft.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
9. 9

   Remove engine mounts
   Attach engine hoist with load leveler to factory engine lifting points on cylinder head or use adjustable lifting brackets bolted to engine. Apply slight upward tension to take weight off mounts. Remove passenger side engine mount-to-frame bolts first, then mount-to-engine bolts. Remove driver side mount using same sequence. Remove front and rear torque rod or torque strut mounts if equipped. Verify all mounts are disconnected and no components are still attached to vehicle.
   ⚠️Ensure engine hoist is properly balanced and engine is secure before removing final mount bolts. Engine can shift suddenly.
   Torque spec

   Engine Mount-to-Block Bolts65 Nm (48 lb-ft)

   Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)
10. 10

    Final disconnection verification and engine removal
    Walk around entire engine compartment and verify all hoses, wiring, cables, and mounts are disconnected. Check underneath for any remaining connections. Slowly raise engine and transmission assembly together, adjusting load leveler angle to clear radiator support and chassis components. An assistant should guide from below while operator controls hoist. Tilt engine as needed (typically nose-up) to clear firewall and strut towers. Once clear of vehicle, lower onto engine stand or work surface.
    ⚠️Move slowly and deliberately. Engine can catch on unseen components causing hoist to tip or damage to vehicle/engine.
11. 11

    Separate transmission from engine on stand
    With engine on stand or secure work surface, remove remaining transmission-to-engine bolts. Carefully pull transmission straight back off engine, supporting weight to prevent input shaft damage. For automatic transmissions, note torque converter position and secure to transmission with wire or converter holding tool. Inspect flywheel/flexplate for damage, cracks, or hot spots. If replacing flywheel bolts (TTY type), remove old bolts and clean threads in crankshaft.
    ℹ️This is ideal time to replace rear main seal, flywheel, and clutch components if needed while engine is out.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
12. 12

    Install engine onto new or rebuilt block
    If installing new or rebuilt engine, transfer all necessary components from old engine: sensors, alternator bracket, A/C compressor bracket, exhaust manifold (with new gasket), accessory drive pulleys, and any other external components. Apply anti-seize to exhaust manifold studs before installing manifold with new gasket. Install flywheel or flexplate with new bolts if TTY type, torquing in star pattern sequence.
    ⚠Flywheel bolts are often torque-to-yield (TTY) and must be replaced with new bolts. Do not reuse old bolts.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
13. 13

    Mate transmission to engine
    Clean transmission bell housing and engine mating surfaces. Install new transmission-to-engine gasket or seal. For automatic transmissions, ensure torque converter is fully seated in transmission pump (typically clicks 2-3 times when pushed in). Apply thin coat of high-temp grease to torque converter pilot or input shaft splines. Align transmission to engine and install all transmission-to-engine bolts, torquing in cross pattern. Install starter motor.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Install engine and transmission assembly into vehicle
    Attach hoist to engine lifting points and raise engine/transmission assembly to vehicle height. Tilt assembly to proper angle (typically nose-up) and carefully guide into engine bay. An assistant should guide from below ensuring proper alignment with mounts and clearance at firewall. Lower slowly while aligning engine mounts with frame brackets. Install engine mount-to-frame bolts first on both sides, then install mount-to-engine bolts. Do not fully torque until all mounts are loosely installed.
    ⚠Ensure proper mount alignment before torquing. Misaligned mounts cause vibration and premature failure.
    Torque spec

    Engine Mount-to-Block Bolts65 Nm (48 lb-ft)

    Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)
15. 15

    Reconnect drivetrain and AWD components
    Install axle shafts into transfer case ensuring retaining clips or bolts are properly secured. Raise front differential into position and install mounting bolts. Align driveshaft to transfer case and front differential using alignment marks made during disassembly. Install driveshaft bolts. Verify all drivetrain components move freely and are properly secured.
    Torque spec

    Alternator Mounting Bolts50 Nm (37 lb-ft)
16. 16

    Reconnect exhaust system
    Raise front exhaust pipe to manifold flange. Install new exhaust manifold gasket if connection was separated at manifold. Install exhaust manifold nuts or flange bolts with anti-seize compound applied to threads. Torque nuts working from center outward. Verify exhaust system has proper clearance and is not contacting frame or body.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
17. 17

    Reinstall accessories and connect wiring
    Install alternator and torque mounting bolts. Install A/C compressor and torque mounting bolts. Install power steering pump if applicable. Route and connect all engine wiring harness connectors using photos taken during disassembly: injectors, coils, sensors, oxygen sensors, and grounds. Connect main ECM connector. Install accessory drive belt following routing diagram.
    Torque spec

    Alternator Mounting Bolts50 Nm (37 lb-ft)

    AC Compressor Bolts25 Nm (18 lb-ft)

    Power Steering Pump Bolts25 Nm (18 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)
18. 18

    Reconnect cooling system and fuel system
    Install radiator assembly and secure mounting brackets. Install radiator cooling fans. Connect upper and lower radiator hoses with new clamps. Connect heater hoses at firewall. Connect transmission cooler lines if equipped. Connect fuel supply and return lines at fuel rail ensuring proper seating. Install air cleaner assembly and intake ducting. Connect mass airflow sensor and all vacuum lines.
19. 19

    Fill fluids and perform initial checks
    Install new oil drain plug crush washer and torque drain plug. Install new oil filter and fill engine with specified amount of 0W-20 engine oil (approximately 5 quarts, verify on dipstick). Fill cooling system with Hyundai/Kia Long Life Green coolant mixed to proper concentration (typically 50/50). Fill transmission with SP-IV-M ATF. Refill transfer case and front/rear differentials with 75W-90 GL-5 gear oil to proper levels. Reconnect battery cables (positive first, then negative). Cycle ignition key to on position several times to prime fuel system without starting.
    ℹ️Do not start engine yet. Perform visual inspection of all connections first.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)
20. 20

    Initial startup and break-in
    Perform final walk-around inspection verifying all connections, no tools left in engine bay, and no visible leaks. Start engine and immediately verify oil pressure light extinguishes. Allow engine to idle and monitor for unusual noises, vibrations, or leaks. Check coolant level in reservoir as air purges from system. Rev engine gently to 2000-3000 RPM several times to circulate oil through new components. Allow engine to reach operating temperature while monitoring temperature gauge. Check for any fluid leaks around all connection points.
    ⚠If oil pressure warning light does not extinguish within 5 seconds, shut down engine immediately and investigate.

Reassembly

1. Torque all engine mount bolts in sequence: loosely install all mounts, then torque mount-to-frame bolts first, followed by mount-to-engine bolts
2. Bleed cooling system completely by running engine with heater on full hot until thermostat opens and coolant circulates through entire system
3. Check transmission fluid level with engine at operating temperature and in park on level ground
4. Verify all electrical connectors are fully seated with locking tabs engaged
5. Install engine splash shields and front wheels, torque lug nuts to specification
6. Install engine cover and any trim panels removed during disassembly
7. Reinstall front bumper cover if removed

Verification

• Start engine and verify smooth idle with no unusual noises, vibrations, or warning lights
• Check for any fluid leaks around engine, transmission, cooling system, and drivetrain connections after engine reaches operating temperature
• Verify all gauges reading properly: oil pressure, coolant temperature, fuel level
• Test drive vehicle verifying proper acceleration, transmission shifting, AWD engagement, and no vibrations
• After test drive, recheck all fluid levels and inspect for leaks with vehicle on lift
• Verify no diagnostic trouble codes (DTCs) stored in engine control module using scan tool
• Recheck engine mount bolt torque after 50-100 miles of driving
• Change engine oil and filter after 500 miles of break-in period for new or rebuilt engine

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