Complete replacement of all engine block freeze plugs on the 2.5L I4 engine, requiring engine removal or significant drivetrain disassembly to access all plugs on both sides of the block.

Warnings

Tools required

Parts

• Freeze plug set (complete engine block) × 1 — Use OEM specification
• Engine coolant × 1 — Hyundai/Kia Long Life Coolant (Green)
• Engine oil and filter × 1 — 0W-20 specification
• Lower radiator hose × 1 — Inspect and replace if damaged
• Engine side cover gaskets × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Motor mount bolts (if reused) × 1 — Use OEM specification
• High-temperature RTV sealant × 1 — Hyundai approved sealant

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 10 qt
• Hyundai Genuine 0W-20 — 5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 3 minutes for airbag system discharge
3. Remove engine cover and plastic undertray panels
4. Drain engine coolant completely into appropriate container
5. Drain engine oil and remove oil filter
6. Remove front wheels and raise vehicle securely on jack stands
7. Remove front skid plate if equipped
8. Photograph and label all electrical connectors for reassembly reference
9. Support transmission with transmission jack before removing engine mounts

Procedure

1. 1

   Remove airbox and intake system
   Disconnect MAF sensor connector. Loosen air intake tube clamps and remove complete air intake assembly including airbox. Remove engine cover mounting brackets to improve access to front of engine.
2. 2

   Disconnect coolant system components
   Remove upper and lower radiator hoses from engine. Disconnect coolant reservoir hose. Remove heater hoses from firewall connections. Label all hoses for correct reinstallation. Plug open ports to prevent debris entry.
   ⚠Verify coolant system is fully drained and depressurized before disconnecting hoses.
3. 3

   Remove accessory drive components
   Remove serpentine belt by rotating tensioner counterclockwise. Remove alternator and set aside with wiring attached. Remove AC compressor mounting bolts and secure compressor without disconnecting refrigerant lines. Remove power steering pump if it restricts access (electric assist system has no fluid lines to disconnect).
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Disconnect exhaust system
   Spray exhaust fasteners with penetrating oil. Disconnect exhaust manifold from catalytic converter at flex joint. Remove exhaust manifold heat shields. Support exhaust system to prevent strain on remaining mounts. On AWD models, note clearance with transfer case.
   ⚠Exhaust components may be brittle. Use penetrating oil and allow time to soak to prevent bolt breakage.
5. 5

   Remove engine mounts and partially lift engine
   Attach engine hoist to factory lift points on engine block. Apply slight upward tension to unload mounts. Remove upper engine mount bolts from frame side. Remove lower mount through-bolts. On AWD models, remove transfer case mounting bracket for clearance. Lift engine 4-6 inches while monitoring all remaining connections.
   ⚠️Verify all electrical, fuel, and coolant connections are disconnected before lifting engine. Ensure hoist chain is secure and rated for engine weight.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
6. 6

   Access driver side freeze plugs
   With engine tilted or raised, identify freeze plug locations on driver side of block. Typically 2-3 plugs are accessible from wheel well area. Remove any remaining brackets or wiring harnesses blocking access. Clean area around freeze plugs to prevent debris from entering coolant passages during removal.
7. 7

   Remove driver side freeze plugs
   Use freeze plug removal tool or drill a small pilot hole in center of each freeze plug (do not drill through block). Thread slide hammer attachment into hole or use angled punch to collapse plug inward at one edge, then pry out. Remove all old sealant and corrosion from freeze plug bore using wire brush. Inspect bore for damage or erosion.
   ⚠Do not drill deeper than freeze plug thickness (approximately 3-4mm). Drilling into coolant jacket will damage block.
8. 8

   Access passenger side and rear freeze plugs
   For full access to passenger side and rear block freeze plugs, engine must be lifted higher or removed completely. Remove remaining engine mount connections. Carefully lift and tilt engine forward while clearing transmission bell housing. On AWD models, ensure clearance from front differential and transfer case. Position engine on stand if removing completely, or support securely while still partially installed.
   ⚠️Passenger side and rear plugs typically require engine removal for safe access. Attempting to replace without proper access risks improper installation.
9. 9

   Remove remaining freeze plugs
   Locate and remove all remaining freeze plugs from passenger side and rear of block using same technique as driver side. Count total plugs removed and verify against engine specification (typically 6-8 total for 2.5L I4). Clean all freeze plug bores thoroughly with wire brush and solvent. Dry completely and inspect for cracks or erosion damage.
10. 10

    Install new freeze plugs
    Apply thin bead of high-temperature RTV sealant around outer edge of new freeze plug as specified in torque specifications. Position freeze plug squarely in bore with cup side facing inward. Use appropriately sized freeze plug driver and dead blow hammer to seat plug flush with block surface or slightly recessed (0.5-1.0mm). For threaded freeze plugs if equipped, apply sealant to threads and torque to specification. Allow sealant to cure per manufacturer instructions before refilling coolant.
    ⚠Freeze plug must be installed perfectly square to bore. Cocked installation will result in coolant leaks. Tap around entire circumference evenly.
    Torque spec

    Freeze Plug10 Nm (7 lb-ft)
11. 11

    Reinstall engine and mounts
    If engine was removed, carefully lower back into engine bay, aligning with transmission bell housing and motor mounts. Guide engine past front differential and transfer case on AWD models. Install motor mount bolts and torque to specification. Remove engine hoist once all mounts are secured. Install transfer case mounting bracket on AWD models.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
12. 12

    Reconnect accessory components
    Reinstall AC compressor and alternator to mounting brackets. Reconnect all electrical connectors to alternator, AC compressor clutch, and other accessories. Install serpentine belt following routing diagram on belt routing label. Verify belt is properly seated in all pulley grooves.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
13. 13

    Reconnect exhaust system
    Position exhaust manifold to catalytic converter connection. Install new gasket if required. Torque exhaust fasteners to specification. Install heat shields. Verify exhaust hangers are properly positioned and system has adequate clearance from driveline components, especially on AWD models.
    Torque spec

    Gasket Bolts20 Nm (15 lb-ft)
14. 14

    Reinstall coolant system components
    Reconnect all coolant hoses to engine block, radiator, and heater core connections. Install new hose clamps and verify proper routing. Reconnect coolant reservoir hose. Ensure all connections are tight and properly positioned to prevent chafing or heat damage.
15. 15

    Refill fluids and bleed cooling system
    Install new engine oil filter and refill with 5.0 quarts of Hyundai Genuine 0W-20 engine oil. Close coolant drain valve. Fill cooling system with 10.0 quarts of Hyundai/Kia Long Life Coolant (Green) through radiator cap or reservoir. Start engine and allow to reach operating temperature with heater on maximum. Monitor coolant level and add as needed to purge air from system. Check for leaks around all freeze plug locations.
    ⚠Monitor freeze plug areas closely during initial heat cycle. Small leaks may not appear until system reaches full pressure and temperature.

Reassembly

1. Reinstall engine cover and plastic undertray panels
2. Install front skid plate if equipped
3. Reinstall front wheels and torque lug nuts to specification
4. Reconnect negative battery cable
5. Reset any diagnostic trouble codes using scan tool
6. Top off all fluid levels after test drive

Verification

• Start engine and verify no coolant leaks from any freeze plug location during cold operation
• Allow engine to reach full operating temperature and recheck all freeze plug areas for leaks under pressure
• Check coolant level after engine cools and top off as necessary
• Verify no oil leaks from disturbed components
• Test drive vehicle and monitor temperature gauge for normal operation
• Recheck coolant level after 100 miles of operation and inspect freeze plugs for any seepage

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