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Home >> Hyundai >> 2020 >> Sonata SEL >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Intake And Exhaust System - 1.6L (Except HEV)) >> EGR Cooler >> Repair Procedures >> Removal And Installation

Removal And Installation

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the battery negative terminal.

    Tightening torque: 

    3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 Ib-ft)

    G14524613Courtesy of HYUNDAI MOTOR AMERICA
  2. Remove the engine cover.
    G14524614Courtesy of HYUNDAI MOTOR AMERICA
  3. Remove the engine room under cover (A).

    Tightening torque: 

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

    Bolt (B): 3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)

    G14524615Courtesy of HYUNDAI MOTOR AMERICA
    G14524616Courtesy of HYUNDAI MOTOR AMERICA
  4. Drain the coolant.
    1. Remove the reservoir tank cap (A).
      G14524617Courtesy of HYUNDAI MOTOR AMERICA
    2. Loosen the drain plug and drain the coolant.
      G14524618Courtesy of HYUNDAI MOTOR AMERICA
  5. Remove the air duct (A).
    G14524619Courtesy of HYUNDAI MOTOR AMERICA
  6. Remove the air cleaner assembly.
    1. Disconnect the RCV hose (A).
    2. Disconnect the breather hose (B).
    3. Disconnect the intake air hose (C).
    4. Disconnect the air flow sensor (AFS) connector (D).
    5. Remove the air cleaner assembly (E).

      Tightening torque: 

      Hose Clamp: 2.9 - 4.9 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)

      Air Cleaner Assembly: 3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 Ib-ft)

      G14524620Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • When install the intake hose, match the alignment marks (A).
        G14524621Courtesy of HYUNDAI MOTOR AMERICA
  7. Remove the battery.
    1. Open the "+" cable cover (A).
      G14524622Courtesy of HYUNDAI MOTOR AMERICA
    2. Loosen the "+" cable mounting nut (B).

      Tightening torque: 

      7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb-ft)

      G14524623Courtesy of HYUNDAI MOTOR AMERICA
    3. Remove the battery mounting bracket (C), and then remove the battery.

      Tightening torque: 

      18.6 - 29.4 N.m (1.9 - 3.0 kgf.m, 13.7 - 21.7 lb-ft)

      G14524624Courtesy of HYUNDAI MOTOR AMERICA
  8. Disconnect the ECM connector (A).
    G14524625Courtesy of HYUNDAI MOTOR AMERICA
  9. Remove the ECM & battery tray (A).

    Tightening torque: 

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

    G14524626Courtesy of HYUNDAI MOTOR AMERICA
  10. Remove the exhaust manifold.

    (Refer to Intake And Exhaust System - "EXHAUST MANIFOLD ")

  11. Disconnect the turbo charger water inlet hose (A).
    G14524627Courtesy of HYUNDAI MOTOR AMERICA
  12. Disconnect EGR outlet hose (A).
    G14524628Courtesy of HYUNDAI MOTOR AMERICA
  13. Disconnect EGR cooler hose A (A).
    G14524629Courtesy of HYUNDAI MOTOR AMERICA
  14. Disconnect EGR hose (A).
    G14524630Courtesy of HYUNDAI MOTOR AMERICA
  15. Remove the EGR cooler & valve (A).

    Tightening torque: 

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

    G14524631Courtesy of HYUNDAI MOTOR AMERICA
  16. Install in the reverse order of removal.
  17. Fill the radiator with coolant.

    Refer to Cooling system - "COOLANT ")

    CAUTION:
    • The coolant must be injected according to the integrated thermal management module (ITM) coolant filling method.
  18. Install in the reverse order of removal.
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