Repair Procedures: Installation

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

NOTE:

Thoroughly clean all parts to be assembled.
Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC.

Install the OCV (Oil Control Valve) filter.

Fig 1: Installing Oil Control Valve Filter
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Keep the OCV filter clean.
Install the cylinder head gasket (A) on the cylinder block.
NOTE:
- Be careful of the installation direction.
- Apply liquid gasket (Loctite 5900H or equivalent) on the edge of cylinder head gasket upside and downside. (At the position 'B')
- After applying sealant, assemble the cylinder head in five minutes.
Fig 2: Installing Cylinder Head Gasket
Courtesy of HYUNDAI MOTOR AMERICA
Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
Install cylinder head bolts.
1. Do not apply engine oil on the cylinder head bolts.
2. Using the SST(09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown in illustration.
Tightening torque: 32.4~36.3 N.m (3.3~3.7 kgf.m, 23.9~26.8 lb-ft) + 90~95° + 90~95°

Fig 3: Cylinder Head Bolts And Plate Washers Tightening Sequence
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Always use new cylinder head bolt.
Install the intake CMPS (Camshaft Position Sensor) (A).
Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 4: Removing/Installing Intake CMPS
Courtesy of HYUNDAI MOTOR AMERICA
Install the exhaust CMPS (Camshaft Position Sensor) (A) and the engine hanger and cam position sensor cover (B).
Tightening torque:

Bolt A: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Bolt B: 27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)

Fig 5: Removing/Installing Exhaust CMPS
Courtesy of HYUNDAI MOTOR AMERICA
Install the intake OCV (Oil Control Valve) (A).
Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 6: Removing/Installing Intake Oil Control Valve
Courtesy of HYUNDAI MOTOR AMERICA
Install the exhaust OCV (Oil Control Valve) (A).
Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 7: Removing/Installing Exhaust Oil Control Valve
Courtesy of HYUNDAI MOTOR AMERICA
CAUTION:
- Do not reuse the OCV when dropped.
- Keep the OCV filter clean.
- Do not hold the OCV sleeve (A) during servicing.
- When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
Fig 8: Identifying Oil Control Valve Sleeve
Courtesy of HYUNDAI MOTOR AMERICA
Install the camshafts.
NOTE: Apply a light coat of engine oil on camshaft journals.
1. Install the exhaust camshaft lower bearing (A).
  
  Fig 9: Removing/Installing Exhaust Camshaft Lower Bearing
  Courtesy of HYUNDAI MOTOR AMERICA
2. Install the camshafts (A).
  
  Fig 10: Identifying Camshafts
  Courtesy of HYUNDAI MOTOR AMERICA
3. Install the exhaust camshaft upper bearing (A) to the front bearing cap.
  
  Fig 11: Installing Exhaust Camshaft Upper Bearing
  Courtesy of HYUNDAI MOTOR AMERICA
4. Install camshaft bearing caps (A) in their proper locations.
  Tightening order: Group A, Group B, Group C.
  
  Tightening torque:
  
  Step 1
  
  M6: 5.9 N.m (0.6 kgf.m, 4.3 lb-ft)
  
  M8: 14.7 N.m (1.5 kgf.m, 10.8 lb-ft)
  
  Step 2
  
  M6: 10.8 ~ 12.7 N.m (1.1 ~ 1.3 kgf.m, 8.0 ~ 9.4 lb-ft)
  
  M8: 27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)
  
  Fig 12: Identifying Camshaft Bearing Caps Tightening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Be careful not to change the position and direction of bearing caps.
Install the intake CVVT assembly (A) and exhaust CVVT assembly (B).
Tightening torque: 53.9 ~ 63.7 N.m (5.5 ~ 6.5 kgf.m, 39.7 ~ 47.0 lb-ft)

Fig 13: Removing/Installing Intake And Exhaust CVVT Assembly
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: When installing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.

Fig 14: Using Wrench To Prevent Camshaft Rotation
Courtesy of HYUNDAI MOTOR AMERICA
Install the intake and exhaust manifold.
(Refer to ENGINE INTAKE & EXHAUST SYSTEM - SONATA HEV article)
Install the timing chain.
(Refer to TIMING SYSTEM - SONATA HEV article)
Check and adjust the valve clearance.
(Refer to VALVE CLEARANCE INSPECTION AND ADJUSTMENT )
Install the water temperature control assembly (A).
Tightening torque:

Bolts: 14.7 ~ 19.6 N.m (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)

Nut: 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

Fig 15: Removing/Installing Water Temperature Control Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Install cylinder head cover.
1. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
2. After applying sealant (Loctite 5900H or equivalent), it should be assembled within 5 minutes.
  Bead width: 2.5 mm (0.10 in.)
  
  Fig 16: Identifying Upper Area Between Timing Chain Cover And Cylinder Head
  Courtesy of HYUNDAI MOTOR AMERICA
3. Install the cylinder head cover (A) by tightening the bolts as following method.
  Tightening torque:
  
  1st step: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
  
  2nd step: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Fig 17: Installing Cylinder Head Cover
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 18: Cylinder Head Cover Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
  CAUTION:
  - Do not reuse cylinder head cover gasket.
  - The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
Connect the water hoses (A). (if equipped)

Fig 19: Identifying Water Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Connect the fuel hose (A) and the PCSV (Purge Control Solenoid Valve) hose (B).

Fig 20: Identifying Fuel Hose And PCSV Hose
Courtesy of HYUNDAI MOTOR AMERICA
Connect the heater hoses.
(Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Connect the wiring connectors and harness clamps, and install the wiring and protectors to the cylinder head and intake manifold.
1. The intake OCV (Oil Control Valve) connector (A)
  
  Fig 21: Identifying Intake Oil Control Valve Connector
  Courtesy of HYUNDAI MOTOR AMERICA
2. The exhaust OCV (Oil Control Valve) connector (A)
  
  Fig 22: Identifying Exhaust Oil Control Valve Connector
  Courtesy of HYUNDAI MOTOR AMERICA
3. The OPS (Oil Pressure Switch) connector (A), the A/C compressor switch connector (B) and the HSG (Hybrid Starter Generator) sensor connector (C)
  
  Fig 23: Identifying Oil Pressure Switch Connector, A/C Compressor Switch Connector And HSG Sensor Connector
  Courtesy of HYUNDAI MOTOR AMERICA
4. The injector connectors (A)
  
  Fig 24: Identifying Injector Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
5. The ignition coil connectors (A)
  
  Fig 25: Identifying Ignition Coil Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
6. The ETC (Electronic Throttle Control) connector (A), the MAPS (Manifold Absolute Pressure Sensor) & IATS (Intake Air Temperature Sensor) connector (B), the knock sensor connector (C) and the intake CMPS (Camshaft Position Sensor) connector (D)
  
  Fig 26: Identifying ETC Connector, MAPS And IATS Connector, Knock Sensor Connector And Intake CMPS Connector
  Courtesy of HYUNDAI MOTOR AMERICA
7. The ECTS (Engine Coolant Temperature Sensor) connector (A), the condenser connector (B), the CKPS (Crankshaft Position Sensor) connector (C), the oxygen sensor connectors (D), the exhaust CMPS (Camshaft Position Sensor) connector (E) and the PCSV (Purge Control Solenoid Valve) connector (F)
Fig 27: Identifying ECTS Connector, Condenser Connector, CKPS Connector, Oxygen Sensor Connectors, Exhaust CMPS Connector And PCSV Connector
Courtesy of HYUNDAI MOTOR AMERICA
Connect the radiator upper hose and lower hose.
(Refer to ENGINE COOLING SYSTEM - SONATA HEV article)
Install the RH front wheel.
(Refer to "WHEEL ")
Install the under covers.
(Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Install the air duct and the air cleaner assembly.
(Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Install the engine cover.
Connect the battery negative terminal in the right side luggage trim.
(Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Install the safety plug in the trunk.
(Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.
NOTE:
- Refill engine with engine oil.
- Refill an engine radiator and a reservoir tank with 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.