INTAKE MANIFOLD
Note. For intake manifold removal and installation procedure for Santa Fe 3.5L, refer to INTAKE MANIFOLD .
THROTTLE BODY
| CAUTION | DO NOT remove throttle valve. DO NOT remove Throttle Position (TP) sensor except for replacement of faulty component. |
Cleaning Throttle Body
- Start engine and allow to idle. Turn ignition off when engine coolant temperature is 176-203°F (80-95°C). Disconnect intake air hose from throttle body. Plug the bypass inlet passage to ensure solvent does not enter the bypass passage. Spray cleaning solvent into throttle body and allow it to soak about 5 minutes. Start engine. Race engine several times to clear solvent. Allow engine to run near idle for one minute.
- Clean all components with solvent except TP sensor and IAC actuator assembly. Check for restrictions in throttle body vacuum ports and passages. Blow out vacuum ports and passages using compressed air. DO NOT remove throttle valve from throttle body. Start engine. Race engine several times to clear solvent. Allow engine to run near idle for one minute.
- Turn ignition off. Remove plug from bypass inlet. Check throttle body for cracks. Ensure accelerator cable moves freely and does not bind or interfere when moving throttle valve. Disconnect negative battery cable for at least 10 seconds to clear any set DTCs. Connect intake air hose.
Using NEW gasket, install throttle body. Tighten mounting bolts and nuts to specification. See TORQUE SPECIFICATIONS . Install vacuum lines, cable(s) and TP sensor connector. After installing accelerator cable, hold exposed portion of cable at center and move cable up and down to ensure slight amount of play exists.
- Using scan tool, retrieve and record all Diagnostic Trouble Codes (DTCs). Ensure ignition switch is in OFF position. Disconnect negative battery cable.
- Locate ECM. See «LOCATING ENGINE CONTROL MODULE (ECM)»(ref-152037-S37818300122004011900000) . Disconnect ECM harness connector. Remove ECM mounting screws or clips. Remove ECM.
- To install, reverse removal procedure. Ensure all harness and cable connections are clean and tight.
| Application | ECM Location |
|---|---|
| Accent | Behind Right Side Of Dash |
| Elantra | Behind Left Side Of Dash Above Kick Panel |
| Santa Fe (2.7L) | Under Center Of Dash |
| Sonata (2.7L) | Under Lower Center Of Dash |
| Tiburon | Behind Right Side Of Dash |
LOCATING ENGINE CONTROL MODULE (ECM)
- Using scan tool, retrieve and record all Diagnostic Trouble Codes (DTCs). Ensure ignition switch is in OFF position. Disconnect negative battery cable.
- Locate PCM. See «LOCATING POWERTRAIN CONTROL MODULE (PCM)»(ref-152037-S04364417432004011900000) . Disconnect PCM harness connector. Remove PCM mounting screws or clips. Remove PCM.
- To install, reverse removal procedure. Ensure all harness and cable connections are clean and tight.
| Application | PCM Location |
|---|---|
| Santa Fe (2.4L) | Under Center Of Dash |
| Sonata (2.4L) | Behind Lower Center Of Dash |
| XG350 | Behind Center Of Dash |
LOCATING POWERTRAIN CONTROL MODULE (PCM)
SENSORS & SWITCHES
Note. Information for Santa Fe models equipped with 3.5L V6 engine is not available from manufacturer.
Disconnect negative battery cable. Locate Camshaft Position (CMP) sensor. See CAMSHAFT POSITION SENSOR LOCATION table. On all models, remove CMP sensor mounting bolt. Disconnect harness connector. Remove CMP sensor from cylinder head. To install, reverse removal procedure.
| Model | Location |
|---|---|
| Accent, Elantra & XG350 | Between Coil & Valve Cover |
| Santa Fe 2.4L & Sonata 2.4L | Between Upper Radiator Hose & Valve Cover |
| Santa Fe 2.7L, Sonata 2.7L & Tiburon 2.7L | Near Thermostat Housing |
| Santa Fe 3.5L | (1) |
| Tiburon 2.0L | At Upper Timing Belt Cover |
| (1) For information on Santa Fe with 3.5L, refer to FUEL SYSTEM (3.5L) article. | |
| (1) | For information on Santa Fe with 3.5L, refer to FUEL SYSTEM (3.5L) article. |
CAMSHAFT POSITION SENSOR LOCATION
THROTTLE POSITION SENSOR
See THROTTLE POSITION (TP) SENSOR in FUEL SYSTEM.
- Turn ignition switch to OFF position. Locate Vehicle Speed Sensor (VSS). (Scheme 9) Disconnect VSS harness connector. Remove VSS mounting screws. Remove VSS.
- To install, reverse removal procedure. Ensure harness connector is securely connected.
Scheme 9
FUEL SYSTEM
Note. For information on Santa Fe with 3.5L, refer to FUEL SYSTEM (3.5L) article.
| WARNING | ALWAYS relieve fuel pressure before disconnecting any fuel injection related component. See FUEL SYSTEM PRESSURE RELEASE . DO NOT allow fuel to contact engine or electrical components. |
Except Accent & Elantra
Open trunk and remove access cover. Disconnect fuel pump harness connector. Start engine and allow it to stall. Turn ignition switch to OFF position. Disconnect negative battery cable and reconnect fuel pump harness connector.
Accent & Elantra
Remove rear seat bottom cushion. Remove fuel pump access cover. Disconnect fuel pump harness connector. Start engine and allow it to stall. Turn ignition switch to OFF position. Disconnect negative battery cable and reconnect fuel pump harness connector.
FUEL FILTER
| WARNING | Always relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components. See FUEL SYSTEM PRESSURE RELEASE . |
Note. On all models except Santa Fe, Sonata and Tiburon, a second fuel filter is part of fuel tank sender and is located inside fuel tank. For removal procedure, see FUEL PUMP .
FUEL PUMP
Note. On Accent, Elantra and Santa Fe, the fuel pressure regulator and fuel return are an integral part of the fuel pump assembly and are located in the fuel tank.
FUEL DELIVERY PIPE & INJECTORS
| CAUTION | When removing fuel delivery pipe, be careful not to drop any fuel injectors. Cover open end of fuel delivery pipe with a shop towel to prevent residual fuel from spilling from delivery pipe. |
Note. On Accent and Elantra, the fuel pressure regulator and fuel return is integral to the fuel pump assembly and is located in fuel tank.
Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Reconnect fuel pump harness connector. Disconnect high-pressure fuel line while covering fitting using shop towel. On all models except Accent, disconnect fuel return line. On all models, disconnect fuel injector harness connector. Remove fuel delivery pipe attaching bolts. Remove fuel delivery pipe with fuel injectors and pressure regulator (if equipped). Rotate injector while pulling outward to remove from fuel delivery pipe. (Scheme 10)- (Scheme 13).
- Install NEW "O" ring to injector. Lightly coat "O" rings (fuel delivery pipe side) with oil. Rotate injector left and right while pushing into fuel delivery pipe. If injector does not turn smoothly, remove injector and check "O" ring for binding. Lightly coat injector "O" rings (intake manifold side) with oil. Position fuel delivery pipe assembly over insulators.
- Install injector and fuel delivery pipe assemblies into intake manifold. Ensure injectors rotate left and right smoothly. If injectors do not rotate smoothly, check "O" ring(s) for binding. Install fuel delivery pipe mounting bolts to intake manifold and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-152037-S10770745552003011300000) . Connect high-pressure fuel and return lines to fuel delivery pipe. Reconnect negative battery cable. Turn ignition on and check for fuel leaks before starting engine. To complete installation, reverse removal procedure.
Scheme 10
Scheme 11
Scheme 12
Scheme 13
THROTTLE POSITION (TP) SENSOR
Note. DO NOT remove TP sensor unless it has tested defective and is being replaced.
Disconnect TP sensor harness connector and remove mounting screws. Remove TP sensor from throttle body. To install, reverse removal procedure. Tighten TP sensor mounting screws to specification. See TORQUE SPECIFICATIONS .
IGNITION SYSTEM
| CAUTION | When battery is disconnected, vehicle computer and memory system may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES - HYUNDAI article in GENERAL INFORMATION before disconnecting battery. |
Note. All models are equipped with a Distributorless Ignition System (DIS).
CAMSHAFT POSITION (CMP) SENSOR
See CAMSHAFT POSITION (CMP) SENSOR under SENSORS & SWITCHES.
CRANKSHAFT POSITION (CKP) SENSOR
See CRANKSHAFT POSITION (CKP) SENSOR under SENSORS & SWITCHES.
KNOCK SENSOR (KS)
See KNOCK SENSOR (KS) under SENSORS & SWITCHES.
SPARK PLUG WIRES
Removal and installation procedure for spark plug wires is not available from the manufacturer. When spark plug wires are replaced, ensure they are installed in correct configuration. (Scheme 14), (Scheme 15) or (Scheme 16).
Scheme 14
Scheme 15
Scheme 16
EMISSION SYSTEMS & SUB-SYSTEMS
Specific removal and installation procedures for emission systems and sub-systems components are not available from the manufacturer. Consult included illustrations to locate desired component(s) and provide visual reference for removal and installation. (Scheme 17)- see scheme 25.
Note. For information on Santa Fe with 3.5L, refer to EMISSION CONTROL (3.5L) article
