Complete long block replacement for 2016-2024 Hyundai Tucson 2.5L I4 AWD engine, including removal of old block assembly and installation of new long block with timing components, oil pump, and cylinder heads.

Warnings

Tools required

Parts

• Long block assembly (2.5L Smartstream engine) × 1 — Use OEM specification
• Timing chain kit with tensioner and guides × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine coolant × 1 — Hyundai/Kia Long Life Coolant (Green)
• Engine oil 0W-20 × 1 — Hyundai Genuine 0W-20
• Oil filter × 1 — Use OEM specification
• Spark plugs × 4 — Use OEM specification
• Engine mount bolts (various) × 1 — Use OEM specification
• Anti-seize compound × 1 — High temperature rated
• RTV silicone sealant × 1 — OEM approved gray RTV

Fluids

• Hyundai Genuine 0W-20 — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 10 qt
• Hyundai SP-IV-M ATF — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable, then positive cable. Wait 10 minutes for airbag system discharge
3. Raise vehicle and secure on jack stands at all four corners
4. Remove engine splash shields and lower covers
5. Drain engine coolant into appropriate container by opening radiator drain and removing lower radiator hose
6. Drain engine oil and remove oil filter
7. Remove front wheels if needed for access to subframe bolts
8. Label and photograph all electrical connectors, vacuum lines, and hose routing before disconnection
9. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
10. Place fender covers to protect vehicle body during engine removal

Procedure

1. 1

   Remove intake and exhaust systems
   Remove air intake tube and air filter housing. Disconnect throttle body electrical connector and remove throttle body. Remove intake manifold by disconnecting all vacuum lines, PCV hoses, and fuel rail. Disconnect exhaust downpipe from catalytic converter at flange. Support exhaust and remove exhaust manifold heat shield, then unbolt exhaust manifold from cylinder head.
2. 2

   Disconnect all engine peripherals and accessories
   Remove accessory drive belt. Remove alternator, A/C compressor (secure aside without disconnecting refrigerant lines), and power steering pump if equipped (this vehicle uses electric power steering). Disconnect all electrical connectors including injectors, ignition coils, camshaft/crankshaft position sensors, oxygen sensors, knock sensor, oil pressure sensor, and coolant temperature sensor. Disconnect fuel supply line and EVAP lines. Remove ignition coils and spark plugs.
3. 3

   Remove cooling system components
   Disconnect upper and lower radiator hoses from engine. Disconnect heater hoses at firewall connections. Remove coolant bypass hoses. If equipped with engine oil cooler, disconnect coolant lines. Label all hose positions for reassembly. Remove radiator fan shroud if it interferes with engine removal.
4. 4

   Separate transmission from engine
   Support transmission with transmission jack. Remove starter motor. Remove all transmission bellhousing-to-engine bolts. For AWD model, mark driveshaft position and remove front driveshaft from transfer case. Disconnect shift cables and transmission wiring harness. Carefully separate transmission from engine by sliding straight back to clear input shaft from clutch disc (manual) or torque converter (automatic). Secure transmission on transmission jack.
   ⚠Transmission weighs approximately 180-200 lbs. Ensure transmission jack is properly positioned and rated for the weight before separating from engine.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
5. 5

   Remove engine mounts and prepare for extraction
   Attach engine hoist with load leveler to factory lifting points on engine block. Take up slack in hoist chain but do not lift yet. Remove left and right engine mount bolts, then front mount bolts. Remove torque strut mount if equipped. Verify all connections, hoses, wiring, and ground straps are disconnected from engine.
   ⚠️Verify engine hoist is rated for minimum 1000 lbs and positioned on stable, level surface. Double-check all attachment points before lifting.
   Torque spec

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

   Extract engine from vehicle
   Slowly lift engine while monitoring clearances around firewall, radiator support, and subframe. Adjust load leveler angle as needed to clear engine bay. Tilt engine as necessary and guide carefully to avoid damage to vehicle body or remaining components. Once clear of engine bay, lower engine onto sturdy engine stand or work surface.
7. 7

   Transfer external components to new long block
   Remove valve cover, timing cover, oil pan, oil pump, water pump, thermostat housing, and any sensors from old engine. Inspect all components for wear or damage and replace as needed. Clean all gasket surfaces on components being transferred. If long block does not include cylinder head, transfer cylinder head following proper removal procedures. Remove flywheel/flexplate from old engine.
   ℹ️Verify exactly which components are included with replacement long block. Some suppliers include oil pan and timing cover, others do not.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)

   Oil Pan Bolts12 Nm (9 lb-ft)
8. 8

   Install timing components on new long block
   Rotate crankshaft to TDC position for cylinder #1 (both camshafts at neutral position). Install timing chain guides and tensioner rail. Route timing chain over crankshaft sprocket, then around camshaft sprockets ensuring timing marks align correctly. Install timing chain tensioner with pin/clip inserted to keep tensioner compressed. Verify all timing marks are properly aligned before releasing tensioner. Remove tensioner pin to allow tensioner to apply proper chain tension.
   ⚠️Incorrect timing chain installation will result in catastrophic engine damage. Triple-check all timing marks before proceeding.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
9. 9

   Install timing cover and oil system components
   Apply thin bead of RTV sealant to timing cover mating surfaces as specified in service manual. Install new timing cover gasket and position timing cover on engine. Install timing cover bolts (8mm) and tighten in proper sequence from center outward. Install oil pump if not already installed. Install oil pan with new gasket, applying thin bead of RTV at block-to-front cover and block-to-rear seal retainer joints. Install oil drain plug with new crush washer.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Drain Plug35 Nm (26 lb-ft)
10. 10

    Install intake and exhaust manifolds
    Install exhaust manifold with new gasket to cylinder head. Apply anti-seize to exhaust manifold stud threads. Install exhaust manifold nuts working from hot (center) to cold (outer) positions. Install intake manifold with new gasket, ensuring all vacuum port passages align correctly. Install intake manifold bolts and tighten in sequence from center outward.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
11. 11

    Install flywheel and valve cover
    Clean flywheel mounting surface on crankshaft. Install flywheel or flexplate using new bolts. Use crankshaft holding tool to prevent rotation. Tighten flywheel bolts in star pattern sequence. Install valve cover with new gasket, ensuring gasket is properly seated in valve cover groove. Tighten valve cover bolts in sequence from center outward.
    ⚠Flywheel bolts are typically TTY type. Use new bolts and do not reuse old bolts.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Cover Bolts16 Nm (12 lb-ft)
12. 12

    Install engine into vehicle
    Attach engine hoist to engine lifting points. Carefully guide engine into engine bay, adjusting angle with load leveler to clear firewall and radiator support. Align engine with transmission and engine mounts. Install engine mount bolts finger-tight initially. Align engine to transmission bellhousing and carefully slide together, ensuring proper pilot bearing or torque converter engagement.
    ⚠Do not force engine and transmission together. If resistance is felt, verify alignment and check for obstructions.
    Torque spec

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

    Connect transmission and install starter
    Install all transmission-to-engine bolts and tighten to specification in cross pattern. For AWD models, reconnect front driveshaft to transfer case aligning marks made during disassembly. Install starter motor. Reconnect shift cables and transmission wiring harness. Tighten all engine mount bolts to specification. Remove engine hoist.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
14. 14

    Reconnect all accessories and peripheral components
    Install alternator, A/C compressor, and any removed accessories. Install new serpentine belt. Reconnect all electrical connectors using labels and photos from disassembly: injectors, ignition coils, sensors (camshaft, crankshaft, knock, oxygen, oil pressure, coolant temperature). Install new spark plugs to specification. Reconnect fuel supply line and EVAP lines. Connect throttle body and install intake air system.
15. 15

    Reconnect cooling system and fill fluids
    Reconnect all coolant hoses: upper radiator, lower radiator, heater hoses, and bypass hoses. Ensure all clamps are properly tightened. Install new oil filter. Fill engine with 5 quarts of Hyundai Genuine 0W-20 oil. Fill cooling system with 10 quarts of Hyundai/Kia Long Life Coolant (Green) mixture through radiator cap and overflow reservoir. Bleed cooling system according to service procedure to remove air pockets.

Reassembly

1. Reinstall engine splash shields and lower covers
2. Install front wheels if removed and torque lug nuts to specification
3. Lower vehicle from jack stands
4. Reconnect positive battery cable, then negative cable
5. Double-check that all tools and parts have been removed from engine bay
6. Verify no fluid leaks visible under vehicle before starting engine

Verification

• Perform visual inspection of all connections, ensuring no loose wiring, hoses, or fasteners
• Check that all fluid levels are correct: engine oil, coolant, transmission fluid
• Prime fuel system by cycling ignition key to ON position 3-4 times without starting
• Start engine and verify oil pressure light extinguishes within 3-5 seconds
• Allow engine to reach operating temperature while monitoring for leaks (coolant, oil, fuel, exhaust)
• Verify no unusual noises, vibrations, or warning lights on instrument cluster
• Check timing by observing idle stability and scanning for timing-related fault codes
• Test drive vehicle and verify proper operation under various loads and speeds
• Recheck all fluid levels after test drive and top off as needed
• Perform final inspection for leaks after test drive and repair if found
• Reset any stored fault codes and verify no new codes appear after several drive cycles
• Torque wheel lug nuts to final specification after test drive

More procedures for this vehicle