Repair Procedures: Removal

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

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 ").

Remove the following items;
1. Engine cover (A).
2. Air cleaner assembly and air duct (B). (Refer to "ENGINE INTAKE & EXHAUST SYSTEM - SONATA HEV article.)
3. Remove the Hybrid Power Control Unit (HPCU) assembly (C).
  (Refer to "HYBRID CONTROL SYSTEM ".)
Fig 1: Identifying Air Cleaner Assembly And Air Duct
Courtesy of HYUNDAI MOTOR AMERICA
Remove the Hybrid Power Control Unit (HPCU) tray (A).
Tightening torque: 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

Fig 2: Identifying Hybrid Power Control Unit (HPCU) Tray
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the heater hose pump connector (B).
Disconnect the heater hose pump (A) from the transaxle.

Fig 3: Identifying Heater Hose Pump Connector
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the solenoid valve connector (A) and inhibitor switch connector (B).

Fig 4: Identifying Solenoid Valve Connector & Inhibitor Switch Connector
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the Electric Oil Pump (EOP) connector (A).

Fig 5: Identifying Electric Oil Pump (EOP) Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the shift cable (C) after removing the nut (A) and the bolt (B).
Tightening torque:

(A) 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

(B) 14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.9 ~ 15.9 lb-ft)

Fig 6: Identifying Shift Cable, Bolt & Nut
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the motor power cable connector (A).

Fig 7: Identifying Motor Power Cable Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the ground line after removing the bolt (A).

Fig 8: Identifying Ground Line & Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the ATF warmer hose (A).

Fig 9: Identifying ATF Warmer Hose
Courtesy of HYUNDAI MOTOR AMERICA
Using the engine support fixture (Support sst No.: 09200-3N000) hold the engine and adapter.
NOTE: * SST No. 09200-38001 model also can be used for removing the transaxle.

Fig 10: Identifying Engine Support Fixture (SST 09200-3N000)
Courtesy of HYUNDAI MOTOR AMERICA
Remove the cover (A).

Fig 11: Identifying Automatic Transaxle Support Bracket Mounting Bolt Cover
Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle support bracket mounting bolt (A).
Tightening torque: 88.2 ~ 107.8 N.m (9.0 ~ 11.0 Kgf.m, 65 ~ 79.5 lb-ft)

Fig 12: Identifying Automatic Transaxle Support Bracket Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle mounting support bracket (A).
Tightening torque: (A) 58.8 ~ 78.4 N.m (6.0 ~ 8.0 kgf.m, 43.3 ~ 57.8 lb-ft)

Fig 13: Identifying Automatic Transaxle Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Remove the sensor connector (A) and (B).

Fig 14: Identifying Sensor Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle upper mounting bolt (A-2 ea).
Tightening torque: (A) 42.2 ~ 54.0 N.m (4.3 ~5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

Fig 15: Identifying Automatic Transaxle Upper Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the under cover (A).
Tightening torque: 7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 lb-ft)

Fig 16: Identifying Front Under Cover
Courtesy of HYUNDAI MOTOR AMERICA
Remove the Electric Oil Pump (EOP) connector (A) and clips (B).
Remove the Clutch Pressure Sensor (CPS) connector (C).

Fig 17: Identifying Electric Oil Pump (EOP) Connector & Clips
Courtesy of HYUNDAI MOTOR AMERICA
Remove the following items;
1. Sub frame assembly.
  (Refer to "FRONT SUSPENSION SYSTEM - SONATA HEV article.)
2. Drive shaft assembly.
  (Refer to "DRIVESHAFT ASSEMBLY - SONATA HEV article.)
Remove the drive shaft cover (A).

Fig 18: Identifying Drive Shaft Cover
Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle with a jack after removing the mounting bolts (A).
Tightening torque: (A) 42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)

Fig 19: Identifying Automatic Transaxle Mounting Bolts
Courtesy of HYUNDAI MOTOR AMERICA