Engine Controls - Removal & Installation: Removal & Installation Hyundai Accent II facelift

Removal & Installation (Elantra)

1. Remove engine cover. Remove air inlet hose from throttle body. Remove PCV valve and brake booster vacuum hose. (Scheme 1) Remove and label any remaining vacuum hoses. Disconnect Throttle Position (TP) sensor and ISC actuator harness connectors.
2. Release pressure from fuel pipe and disconnect high pressure hose. See «FUEL SYSTEM PRESSURE RELEASE»(ref-152037-S04539928132003011300000) in FUEL SYSTEM.
3. Disconnect fuel injector harness connectors. Remove delivery pipe with fuel injectors and pressure regulator attached. Take care not to drop injectors.
4. Remove intake manifold assembly and gasket. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-152037-S10770745552003011300000). Check for fluid and vacuum leaks.

Scheme 1

Removal & Installation (Santa Fe 2.4L & Sonata 2.4L)

1. Remove air breather hose connected to throttle body. Remove throttle cable. Remove coolant hose. Remove throttle body. See «THROTTLE BODY»(ref-152037-S38388968762003011300000). (Scheme 2)
2. Remove PCV valve and brake booster vacuum hose. Label and remove any remaining vacuum hoses. Remove injector cover. Release pressure from fuel pipe and disconnect high pressure hose. See «FUEL SYSTEM PRESSURE RELEASE»(ref-152037-S04539928132003011300000) in FUEL SYSTEM. Disconnect fuel injector harness connectors. Remove delivery pipe with fuel injectors and pressure regulator attached. Take care not to drop injectors.
3. Remove intake manifold stay. Remove intake manifold bolts. Remove intake manifold. Clean all gasket mating surfaces.
4. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-152037-S10770745552003011300000). Check for fluid and vacuum leaks.

Scheme 2

Removal & Installation (Santa Fe 2.7L, Sonata 2.7L, Tiburon 2.7L & XG350)

1. Remove air breather hose connected to throttle body. Remove throttle and cruise control cables. Remove coolant hose. Remove throttle body. See «THROTTLE BODY»(ref-152037-S38388968762003011300000). (Scheme 3)
2. Remove PCV valve and brake booster vacuum hose. Label and remove any remaining vacuum hoses. Remove surge tank stay. Release pressure from fuel pipe and disconnect high pressure hose. See «FUEL SYSTEM PRESSURE RELEASE»(ref-152037-S04539928132003011300000) in FUEL SYSTEM. Disconnect high pressure hose. Remove surge tank and gasket.
3. Disconnect fuel injector harness connectors. Disconnect fuel injector harness connectors. Remove delivery pipe with fuel injectors and pressure regulator attached. Take care not to drop an injector. Disconnect coolant sensor harness connector. Remove intake manifold bolts. Remove intake manifold. Clean all gasket mating surfaces.
4. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-152037-S10770745552003011300000). Check for fluid and vacuum leaks.

Scheme 3

Removal & Installation (Accent 1.6L & Tiburon 2.0L)

1. Remove engine cover. Remove air inlet hose from throttle body. Remove PCV valve and brake booster vacuum hose. (Scheme 4) Remove and label any remaining vacuum hoses. Disconnect Throttle Position (TP) sensor and ISC actuator harness connectors.
2. Release pressure from fuel pipe and disconnect high pressure hose. See «FUEL SYSTEM PRESSURE RELEASE»(ref-152037-S04539928132003011300000) in FUEL SYSTEM.
3. Disconnect fuel injector harness connectors. Remove delivery pipe with fuel injectors and pressure regulator attached. Take care not to drop injectors.
4. Remove intake manifold assembly and gasket. Check all components for damage or excessive wear. Replace as necessary. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-152037-S10770745552003011300000). Check for fluid and vacuum leaks.

Scheme 4

Removal (Models Equipped With 4-Cylinder Engine)

Disconnect negative battery cable. Disconnect accelerator cable from throttle valve lever and cable bracket. Disconnect TP sensor connector. Label and disconnect all vacuum hoses from throttle body. Remove throttle body from intake manifold. (Scheme 1), (Scheme 2) or (Scheme 4).

Removal (Models Equipped With V6 Engine)

Note. Cleaning procedure on this application MUST be accomplished prior to removal.

Disconnect negative battery cable. Disconnect accelerator and cruise control cables from throttle valve lever and cable bracket. Disconnect TP sensor connector. Label and disconnect all hoses from throttle body. Remove throttle body from intake manifold. (Scheme 3)

Removal & Installation (Except Santa Fe 2.7L, Sonata 2.7L & Tiburon 2.7L)

Disconnect negative battery cable. Locate Crankshaft Position (CKP) sensor, near crankshaft pulley. Remove CKP sensor mounting bolt. Pull CKP sensor from engine block and disconnect harness connector. To install, reverse removal procedure.

Removal & Installation (Santa Fe 2.7L, Sonata 2.7L & Tiburon 2.7L)

Disconnect negative battery cable. Locate Crankshaft Position (CKP) sensor near the coil, at end of head. Remove CKP mounting bolt. Remove sensor and disconnect harness connector. To install, reverse removal procedure.

1. Turn ignition switch to OFF position. Locate Engine Coolant Temperature (ECT) sensor at thermostat housing. Disconnect harness connector. Using wrench or appropriate removal tool, remove ECT sensor. Clean excessive sealant from thermostat housing threads (if applicable).
2. Add sealant to ECT sensor threads (if applicable). To install, reverse removal procedure. Tighten ECT sensor to specification. See «TORQUE SPECIFICATIONS»(ref-152037-S10770745552003011300000) . Refill cooling system and check for leaks.

1. Front HO2S is mounted in exhaust pipe in front of catalytic converter. Rear HO2S is located after the catalytic converter. HO2S has a permanent pigtail which must be protected from damage when removing sensor. DO NOT use any cleaning solvents. Ensure exhaust system is cool before removing HO2S, or thread damage may occur.
2. Disconnect negative battery cable and HO2S connector. Remove HO2S. To install, reverse removal procedure. Ensure sensor is free of contaminants. If reinstalling old sensor, apply anti-seize compound to HO2S threads. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-152037-S10770745552003011300000) . Reconnect negative battery cable.

1. Turn ignition switch to OFF position. Locate ISC actuator valve. (Scheme 5)and (Scheme 6). Disconnect ISC actuator harness connector. Disconnect by-pass hose. Remove ISC actuator from the throttle valve.
2. To install, reverse removal procedure. Ensure by-pass hose and harness connector are securely connected.

Scheme 5

Scheme 6

Locate MAF sensor. (Scheme 7) Turn ignition switch to OFF position. Disconnect harness connector. Remove MAF sensor. To Install, reverse removal procedure.

Scheme 7

Turn ignition switch to OFF position. Locate Manifold Absolute Pressure (MAP) sensor. (Scheme 5)or (Scheme 6). Disconnect MAP sensor harness connector. Remove mounting bolts and MAP sensor. To install, reverse removal procedure. Ensure harness connector is securely connected.

1. Turn ignition switch to OFF position. Locate Knock sensor (KS) on side of cylinder block. (Scheme 8) Remove KS mounting bolt. Remove KS.
2. To install, reverse removal procedure. Tighten KS to specification. See «TORQUE SPECIFICATIONS»(ref-152037-S10770745552003011300000).

Scheme 8

Removal & Installation (Accent & Elantra)

Remove rear seat bottom cushion and fuel tank sender access cover. See FUEL FILTER LOCATIONS table. Remove fuel tank filler cap to release fuel tank pressure. Remove ground connector and fuel lines from filter. Remove fuel filter. To install, reverse removal procedure. Pressure test fuel system and check for leaks.

Removal & Installation (XG350)

Locate fuel filter. See FUEL FILTER LOCATIONS table. Remove fuel lines from filter. Remove fuel filter clamp bolt and remove filter. To install, reverse removal procedure. Pressure test fuel system and check for leaks.

FUEL FILTER LOCATIONS

Removal (Accent & Elantra)

1. Remove rear seat bottom cushion and fuel pump access cover. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-152037-S04539928132003011300000) . Disconnect negative battery cable.
2. Remove fuel tank filler cap to release fuel tank pressure. Disconnect fuel pump and sender harness connector. Disconnect high-pressure and fuel return lines at fuel tank. Cover high-pressure hose connection with shop towels to prevent fuel leakage. Remove fuel gauge sending unit retaining screws and remove fuel tank sending unit assembly from tank. Remove fuel pump from sending unit assembly.

Installation (Accent & Elantra)

Install fuel pump to gauge sending unit assembly. Install fuel pump and gauge sending unit assembly into fuel tank, using care not to pinch "O" ring. Reinstall retaining screws. Connect pressure and fuel return lines to fuel pump and carefully tighten fittings to specification. See TORQUE SPECIFICATIONS . Ensure fuel lines do not twist or bend. Energize fuel pump and check for fuel leaks. To complete installation, reverse removal procedure.

Removal (Santa Fe)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-152037-S04539928132003011300000) . Disconnect negative battery cable.
2. Remove fuel tank filler cap to release fuel tank pressure. Raise vehicle and disconnect fuel pump harness connector. Remove fuel feed and return hoses from fuel pump assembly. Remove fuel pump installation screws. Remove fuel pump assembly from fuel tank.
3. Remove fuel level sender and fuel filter from fuel pump assembly. Inspect and replace fuel pump if necessary.

Installation (Santa Fe)

Install fuel pump to gauge sending unit assembly. Install fuel pump and gauge sending unit assembly into fuel tank, using care not to pinch "O" ring. Reinstall retaining screws. Connect pressure and fuel return lines to fuel pump and carefully tighten fittings to specification. See TORQUE SPECIFICATIONS . Ensure fuel lines do not twist or bend. Energize fuel pump and check for fuel leaks. To complete installation, reverse removal procedure.

Removal (Sonata, Tiburon & XG350)

1. Open trunk and remove fuel pump access cover. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-152037-S04539928132003011300000) . Disconnect negative battery cable.
2. Remove fuel tank filler cap to release fuel tank pressure. Disconnect fuel pump and sender harness connector. Disconnect high-pressure and fuel return lines at fuel tank. Cover high-pressure hose connection with shop towels to prevent fuel leakage. Remove fuel gauge sending unit retaining screws and remove fuel tank sending unit assembly from tank. Remove fuel pump from sending unit assembly.

Installation (Sonata, Tiburon & XG350)

Install fuel pump to gauge sending unit assembly. Install fuel pump and gauge sending unit assembly into fuel tank, using care not to pinch "O" ring. Reinstall retaining screws. Connect pressure and fuel return lines to fuel pump and carefully tighten fittings to specification. See TORQUE SPECIFICATIONS . Ensure fuel lines do not twist or bend. Energize fuel pump and check for fuel leaks. To complete installation, reverse removal procedure.