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Home >> Hyundai >> 2020 >> Sonata SEL >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 8 (Cylinder Head Assembly - 1.6L (Except HEV)) >> Cylinder Head >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.
NOTE:
  • Use Fender cover 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.

Information 

  1. Disconnect the battery negative terminal.

    Tightening torque: 

    4.0 - 6.0 N.m (0.4 - 0.6 kgf.m, 3.0 - 4.4 lb-ft)

    G14524274Courtesy of HYUNDAI MOTOR AMERICA
  2. Remove the engine cover.
    G14524275Courtesy of HYUNDAI MOTOR AMERICA
  3. Remove the engine room under cover (A).

    Tightening torque: 

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

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

    G14524276Courtesy of HYUNDAI MOTOR AMERICA
    G14524277Courtesy of HYUNDAI MOTOR AMERICA
  4. Drain the coolant.
    1. Remove the reservoir tank cap (A).
      G14524278Courtesy of HYUNDAI MOTOR AMERICA
    2. Loosen the drain plug (A), and drain the coolant.
  5. Remove the air duct (A).
    G14524279Courtesy 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 and Clamps: 2.9 - 4.9 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)

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

    G14524280Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When install the intake hose, match the alignment marks (A).
    G14524281Courtesy of HYUNDAI MOTOR AMERICA
  7. Remove the battery
    1. Open the "+" cable cover (A).
      G14524282Courtesy 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)

      G14524283Courtesy of HYUNDAI MOTOR AMERICA
    3. Remove the battery after removing the mounting bracket (C).

      Tightening torque: 

      19.6 - 29.4 N.m (1.9 - 3.0 kgf.m, 13.7 - 30.4 Ib-ft)

    G14524284Courtesy of HYUNDAI MOTOR AMERICA
  8. Disconnect the ECM connectors (A).
    G14524285Courtesy of HYUNDAI MOTOR AMERICA
  9. Remove the ECM and battery tray (A).

    Tightening torque: 

    19.6 - 29.4 N.m (1.9 - 3.0 kgf.m, 13.7 - 30.4 Ib-ft)

    G14524286Courtesy of HYUNDAI MOTOR AMERICA
  10. Disconnect the radiator upper hose (A).
    G14524287Courtesy of HYUNDAI MOTOR AMERICA
  11. Remove the engine ground cable (A).
    G14524288Courtesy of HYUNDAI MOTOR AMERICA
  12. Disconnect the reservoir tank coolant hose (A).
    G14524289Courtesy of HYUNDAI MOTOR AMERICA
  13. Disconnect the heater hoses (A).
    G14524290Courtesy of HYUNDAI MOTOR AMERICA
  14. Disconnect the brake vacuum hose (A).
    G14524291Courtesy of HYUNDAI MOTOR AMERICA
  15. Disconnect the fuel hose (A) and purge control solenoid valve (PCSV) hose (B).
    G14524292Courtesy of HYUNDAI MOTOR AMERICA
  16. Remove the intake manifold.

    (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")

  17. Remove the delivery pipe.

    (Refer to Engine Control/Fuel System - "DELIVERY PIPE ")

  18. Remove the exhaust manifold.

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

  19. Remove the vacuum pump (A).
    G14524293Courtesy of HYUNDAI MOTOR AMERICA
  20. Remove the integrated thermal management module (ITM).

    (Refer to Cooling System - "INTEGRATED THERMAL MANAGEMENT MODULE (ITM) ")

  21. Remove the heater pipe mounting bolts (A).
    G14524294Courtesy of HYUNDAI MOTOR AMERICA
  22. Remove the spark plug.

    (Refer to Engine Electrical System - "SPARK PLUG ")

  23. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

  24. Remove the camshaft front bearing cap (A) and camshaft bearing caps (B).
    G14524295Courtesy of HYUNDAI MOTOR AMERICA
  25. Remove the CVVD assembly.
    NOTE:
    • After removing the CVVD unit, make sure that the parts such as lifter, cam, etc are not separated.
    • Ensure that the CVVD components are not damaged.

    When Using the CVVD fixture 

    1. Install the CVVD fixture (A) over the CVVD assembly.
      G14524296Courtesy of HYUNDAI MOTOR AMERICA
      G14524297Courtesy of HYUNDAI MOTOR AMERICA
    2. Remove the CVVD assembly.
    G14524298Courtesy of HYUNDAI MOTOR AMERICA

    When not using the CVVD fixture 

    1. Remove the CVVD assembly.
    G14524299Courtesy of HYUNDAI MOTOR AMERICA
  26. Remove the exhaust camshaft & CVVT assembly (A).
    G14524300Courtesy of HYUNDAI MOTOR AMERICA
  27. Remove the cylinder head heat protector (A).
    G14524301Courtesy of HYUNDAI MOTOR AMERICA
  28. Remove the cylinder head degassing water hose and pipe (A).
    G14524302Courtesy of HYUNDAI MOTOR AMERICA
  29. Remove the cam carrier (A).
    G14524303Courtesy of HYUNDAI MOTOR AMERICA
  30. Remove the hydraulic lash adjuster (HLA) (A) and swing arm (B).
    G14524304Courtesy of HYUNDAI MOTOR AMERICA
  31. Remove the cylinder head.
    1. Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.
      Fig 1: Cylinder Head Bolts Loosening Sequence
      G14524305Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • Removing cylinder head bolts in an incorrect order may result in head warpage or crack.
      • Use dodecagonal driver socket that has under 15 mm (0.5906 in.) external diameter and longer than 75 mm (2.9528 in.) cylinder to not have interference between cylinder head and dodecagonal driver socket when the cylinder head bolt removal.

        Removing cylinder head bolts in an incorrect order may result in head warpage or crack.

      G14524306Courtesy of HYUNDAI MOTOR AMERICA
    2. Lift the cylinder head (A) from the cylinder block and put the cylinder head on wooden blocks.
      G14524307Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
    3. Remove the cylinder head gasket (A).
      G14524308Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • Do not reuse the cylinder head gasket.
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