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 damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE: Mark all wiring and hoses to avoid misconnection.

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.
Remove the air duct and the air cleaner assembly.
(Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Remove the under covers.
(Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Remove the RH front wheel.
(Refer to "WHEEL ")
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)
Disconnect the radiator upper hose and lower hose.
(Refer to ENGINE COOLING SYSTEM - SONATA HEV article)
Disconnect the wiring connectors and harness clamps, and remove the wiring and protectors from the cylinder head and intake manifold.
1. The intake OCV (Oil Control Valve) connector (A)
  
  Fig 1: Identifying Intake Oil Control Valve Connector
  Courtesy of HYUNDAI MOTOR AMERICA
2. The exhaust OCV (Oil Control Valve) connector (A)
  
  Fig 2: 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 3: 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 4: Identifying Injector Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
5. The ignition coil connectors (A)
  
  Fig 5: 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 6: Identifying ETC Connector, MAPS, IATS Connector And 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 7: Identifying ECTS Connector, Condenser Connector, CKPS Connector, Oxygen Sensor Connectors, Exhaust CMPS Connector And PCSV Connector
  Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the heater hoses.
(Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 8: Identifying Fuel Hose And PCSV Hose
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the water hoses (A).

Fig 9: Identifying Water Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Remove the water temperature control assembly (A).

Fig 10: Removing/Installing Water Temperature Control Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Remove the timing chain.
(Refer to TIMING SYSTEM - SONATA HEV article)
Remove the intake and exhaust manifold.
(Refer to ENGINE INTAKE & EXHAUST SYSTEM - SONATA HEV article)
Remove the intake CVVT assembly (A) and exhaust CVVT assembly (B).

Fig 11: Removing/Installing Intake And Exhaust CVVT Assembly
Courtesy of HYUNDAI MOTOR AMERICA

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

Fig 12: Using Wrench To Prevent Camshaft Rotation
Courtesy of HYUNDAI MOTOR AMERICA
Remove the camshaft.
1. Remove the front camshaft bearing cap (A) with the upper bearing (B).
  
  Fig 13: Removing Front Camshaft Bearing Cap And Upper Bearing
  Courtesy of HYUNDAI MOTOR AMERICA
2. Remove the camshaft bearing cap (A) in the sequence shown in illustration.
  
  Fig 14: Camshaft Bearing Cap Bolt Removal Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
3. Remove the camshafts (A).
  
  Fig 15: Identifying Camshafts
  Courtesy of HYUNDAI MOTOR AMERICA
4. Remove the exhaust camshaft lower bearing (A).
Fig 16: Removing/Installing Exhaust Camshaft Lower Bearing
Courtesy of HYUNDAI MOTOR AMERICA
Remove the intake OCV (Oil Control Valve) (A) using a Torx wrench.

Fig 17: Removing/Installing Intake Oil Control Valve
Courtesy of HYUNDAI MOTOR AMERICA
Remove the exhaust OCV (Oil Control Valve) (A) using a Torx wrench.

Fig 18: Removing/Installing Exhaust Oil Control Valve
Courtesy of HYUNDAI MOTOR AMERICA
Remove the intake CMPS (Camshaft Position Sensor) (A).

Fig 19: Removing/Installing Intake CMPS
Courtesy of HYUNDAI MOTOR AMERICA
Remove the exhaust CMPS (Camshaft Position Sensor) (A) after removing the engine hanger and cam position sensor cover (B).

Fig 20: Removing/Installing Exhaust CMPS
Courtesy of HYUNDAI MOTOR AMERICA
Remove the cylinder head.
1. Using triple square wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown in illustration. Remove the 10 cylinder head bolts and plate washers.
  
  Fig 21: Cylinder Head Bolts Removal Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order.
2. Lift the cylinder head (A) from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.
  CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
3. Remove the cylinder head gasket (B).
  
  Fig 22: Cylinder Head & Gasket
  Courtesy of HYUNDAI MOTOR AMERICA