Repair procedures: Removal

WARNING: This page is about a different variant/trim than selected.

CAUTION:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:

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.

WARNING: The hybrid system uses DC 270V high voltage. So, be sure to follow safety instructions below. Otherwise, there may be a serious injury or electrocution (Refer to "SAFETY PRECAUTION ").

Shut off the High Voltage circuit.
(Refer to "HIGH VOLTAGE SHUTOFF PROCEDURE ")
Remove the engine cover (A).

Fig 1: Identifying Engine Cover
Courtesy of HYUNDAI MOTOR AMERICA
Remove the air duct (A).
Tightening torque: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

Fig 2: Identifying Air Duct
Courtesy of HYUNDAI MOTOR AMERICA
Remove the air cleaner assembly.
1. Disconnect the breather hose (A).
2. Disconnect the air intake hose (B) and then remove the air cleaner assembly (C).
  Tightening torque:
  
  Hose clamp bolt:
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Fig 3: Identifying Breather Hose, Air Cleaner Assembly, And Air Intake Hose
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - When installing the air intake hose, the plate of the hose clamp must be in line with the stopper of the hose.
  - When installing the air intake hose, the center of the mark of hose must be in line with the throttle body rib.
  Fig 4: Identifying Plate Of Hose Clamp
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Do not replace HC trap element (A) as it can be used semi-permanently.
  
  Fig 5: Identifying HC Trap Element
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the under covers (A, B).
Tightening torque: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 6: Identifying Under Covers
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: When removing the under cover (B), unfasten the mounting bracket bolts and then remove the under cover and mounting bracket assembly.
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to ENGINE COOLING SYSTEM - SONATA HEV article)
Loosen the drain plug, and drain the inverter coolant. Remove the reservoir cap to help drain the coolant faster. (Refer to "COOLANT ")
Disconnect the radiator upper hose (A) and lower hose (B).

Fig 7: Identifying Radiator Upper Hose And Lower Hose
Courtesy of HYUNDAI MOTOR AMERICA
Remove the HPCU (Hybrid Power Control Unit).
(Refer to "HPCU (Hybrid Power Control Unit) ")
Remove the inverter tray (A).
Tightening torque: 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

Fig 8: Identifying Inverter Tray
Courtesy of HYUNDAI MOTOR AMERICA
Recover the refrigerant and then remove the high pressure pipe (A) and low pressure pipe (B).
(Refer to "ELECTRIC AC COMPRESSOR ")

Fig 9: Identifying High Pressure Pipe And Low Pressure Pipe
Courtesy of HYUNDAI MOTOR AMERICA
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).

Fig 10: Identifying ECM Connectors, Fuse Box Connector, Engine Ground Line And Wiring Protector
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the cooling hoses from HSG (Hybrid Starter Generator) (A) and EWP (Electric Water Pump) (B).

Fig 11: Identifying Cooling Hoses And Electric Water Pump
Courtesy of HYUNDAI MOTOR AMERICA
Remove the transaxle wire harness connectors and control cable from the transaxle.
(Refer to AUTOMATIC TRANSAXLE SYSTEM - SONATA HEV article).
Disconnect the heater hoses (A).

Fig 12: Identifying Heater Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel hose (A) and the PCSV (Purge Control Solenoid Valve) hose (B).

Fig 13: Identifying Fuel Hose And Purge Control Solenoid Valve Hose
Courtesy of HYUNDAI MOTOR AMERICA
Remove the front muffler (A).

Fig 14: Identifying Front Muffler
Courtesy of HYUNDAI MOTOR AMERICA
Remove the steering u-joint mounting bolt (A).
(Refer to ELECTRIC POWER STEERING - SONATA HEV article)

Fig 15: Identifying U-Joint Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the front wheels.
(Refer to "WHEEL ")
Remove the lower arms (A).
(Refer to "FRONT LOWER ARM ")

Fig 16: Removing Lower Arms
Courtesy of HYUNDAI MOTOR AMERICA
Remove the stabilizer bar links (A).
(Refer to "FRONT STABILIZER BAR ")

Fig 17: Removing Stabilizer Bar Links
Courtesy of HYUNDAI MOTOR AMERICA
Remove the tie rod ends (A).
(Refer to "STEERING GEAR BOX ")

Fig 18: Removing Tie Rod Ends
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the drive shafts (A) from the axle hubs.
(Refer to "FRONT HUB/KNUCKLE ")

Fig 19: Identifying Drive Shaft
Courtesy of HYUNDAI MOTOR AMERICA
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)

Bolt (C):

49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

Fig 20: Removing Roll Rod Bracket
Courtesy of HYUNDAI MOTOR AMERICA
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)

Fig 21: Removing Roll Rod Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts.
(Refer to "FRONT CROSS MEMBER ")

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)

Fig 22: Removing Sub Frame Mounting Bolts And Nuts
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
- After removing the sub frame mounting bolts and nuts, 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.
Support the engine and transaxle assembly with a floor jack, and then disconnect the ground line (A) and remove the engine mounting support bracket (B).
Tightening torque: 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Fig 23: Removing Ground Line & Engine Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ground line (A).

Fig 24: Identifying Ground Line
Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle support bracket mounting bolt (B) after removing the cover (A).
Tightening torque: 88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

Fig 25: Identifying Cover
Courtesy of HYUNDAI MOTOR AMERICA

Fig 26: Identifying Automatic Transaxle Support Bracket Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Lower floor jack with the engine and transaxle assembly, and then remove the engine and transaxle assembly by lifting vehicle.

Fig 27: Removing Engine And Transaxle Assembly
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.