Hyundai Sonata: Engine And Transmission Assembly Repair procedures - Engine And Transmission Assembly - Engine Mechanical SystemHyundai Sonata: Engine And Transmission Assembly Repair procedures

Removal
1.
Remove the engine cover.
2.
Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
3.
Remove the air duct and air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
4.
Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
5.
Drain the engine coolant.
(Refer to Cooling System - "Coolant")
6.
Remove the intercooler inlet hoses & pipe (A).

Tightening torque
Bolt :
19.6 ~ 26.4 N.m (2.0 ~ 2.7 kgf.m, 14.4 ~ 19.5 lb-ft)
Clamp :
4.9 ~ 6.8 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.0 lb-ft)

7.
Disconnect the radiator upper hose (A).

8.
Disconnect the radiator lower hose (A).

9.
Remove the intercooler outlet hose (A).

Tightening torque:
4.9 ~ 6.8 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.0 lb-ft)

10.
Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.
(Refer to Heating, Ventilation Air conditioning - "Compressor")
11.
Remove the transaxle wire harness connectors and control cable from the transaxle.
(Refer to Automatic Transaxle System - "Automatic Transaxle")
12.
Disconnect the brake booster vacuum hose (A).

13.
Disconnect the heater hoses (A).

   
When installing the heater hoses, install as shown in illustrations.

14.
Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).

15.
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).

16.
Disconnect the vacuum hose(A).

17.
Disconnect the (+) cable (A) from the fuse/relay box and the front connector (B). Then remove the wiring protector (C).

18.
Remove the front muffler.
(Refer to Intake And Exhaust System - "Muffler")
19.
Remove the steering u-joint mounting bolt.
(Refer to Steering System - "Electric Power Steering")
20.
Remove the roll rod bracket (A).

Tightening torque
Bolt (B):
107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Bolts (C):
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

21.
Remove the roll rod mounting support bracket (A).

Tightening torque:
49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

22.
Remove the sub frame.
(Refer to Suspension system - "Sub frame")
23.
Support the engine and transaxle assembly with a floor jack.
24.
Disconnect the ground cable (A) and then remove the engine mounting support bracket (B).

Tightening torque :
Ground cable : 10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
Support bracket : 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

25.
Disconnect the ground line (A).

26.
Remove the service cover (A).

27.
Remove the transaxle mounting bolts (A).

Tightening torque :
107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)

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

   
Before removing the engine and transaxle assembly, make sure hoses and wire connectors are disconnected.
When removing 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.
Adjust the throttle cable.
Refill engine with engine oil.
Refill a transaxle with fluid.
Refill power steering fluid.
Refill a radiator and a reservoir tank with engine coolant.
Place a heater control knob on "HOT" position.
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.
    Engine Mounting Repair procedures
    Removal and Installation Rollroad Mounting 1. Rollroad bracket mounting bolts and rollroad bracket (A). Tightening torque Bolt (B) : 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft) ...

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