Hyundai Sonata: Repair procedures - Engine And Transaxle Assembly - Engine Mechanical SystemHyundai Sonata: 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.
Remove the engine cover.
2.
Disconnect the battery terminals (A).
Tightening torque :
(+) terminal : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
(-) terminal : 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
3.
Remove the air duct (B).
4.
Remove the battery (A) after removing the mounting bracket (B).
Tightening torque:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

5.
Remove the air cleaner assembly.
(1)
Disconnect the breather hose (A), the intensifier hose (B) and brake booster vacuum hose (C).
(2)
Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).
Tightening torque
Hose clamp bolt:
2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Air cleaner assembly bolts:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

6.
Remove the battery tray (A).
Tightening torque:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

7.
Remove the under covers.
8.
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.
(Refer to Cooling system in this group)
9.
Disconnect the radiator upper hose (A) and lower hose (B).
10.
Recover the refrigerant and then remove the high pressure pipe and low pressure pipe (A).
(Refer to Air conditioning system in HA Group.)
11.
Disconnect the (+) cable (A) from the fuse/relay box and the front connector (B). Then remove the wiring protector (C).
12.
Disconnect the ECM connectors (A) from the ECM, the fuse box connector (B) from the fuse/relay box and the engine ground line (C). Then remove the wiring protector (D).

13.
Remove the transaxle wire harness connectors (A) and control cable (B) from the transaxle.
(Refer to AT or MT group)
14.
Disconnect the ATF cooler hoses (A).
15.
Disconnect the heater hoses (A).
16.
Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).
17.
Remove the front muffler (B) after disconnecting the front oxygen sensor connector (A) (ULEV only).
Tightening torque:
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

18.
Remove the steering u-joint mounting bolt (A).
(Refer to ST group)
19.
Remove the front wheels.
20.
Remove the lower arms (A).
(Refer to SS group)
21.
Remove the stabilizer bar links (A).
(Refer to SS group)
22.
Remove the tie rod ends (A). (Refer to ST group)
23.
Disconnect the drive shafts from the axle hubs.
(Refer to DS group)
24.
Remove the roll rod bracket (A).
Tightening torque:
Nut (B) : 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Bolt (C) : 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

25.
Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts.
Tightening torque:
Sub frame mounting bolts & nuts :
156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)
Stay mounting bolts :
44.1 ~ 58.8 N.m (4.5 ~ 6.0 kgf.m, 32.5 ~ 43.4 lb-ft)

•
After removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them securely with floor jack.
•
Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
26.
Disconnect the ground line (A), and then remove the engine mounting bracket (B).
Tightening torque:
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

27.
Disconnect the ground line (A), and then remove the transaxle mounting support bracket (B).
Tightening torque:
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

28.
Remove the engine and transaxle assembly by lifting vehicle.

When remove 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.
•
Clean battery posts and cable terminals and assemble.
•
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.
•
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.
-
Put radiator cap on tightly, then run the engine again and check for leaks.

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