Engine Controls - Remove/install/overhaul Hyundai Elantra I

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Removal

Disconnect negative battery cable. Remove distributor cap and spark plug wires. Turn crankshaft until No. 1 cylinder is at top dead center (TDC) of compression stroke. Note direction of rotor for installation. Disconnect distributor lead wire connector. Remove distributor hold-down nut and washer. Remove distributor assembly.

Disassembly

1. Lightly clamp distributor in soft-jawed vise. Remove rotor screw (3.0L) rotor, gasket and plastic cover. (Scheme 1)or (Scheme 2). Remove rotor shaft screw. Remove rotor shaft (using puller if necessary).
2. Remove optical disc and spacer(s). Disconnect lead wire connector. Remove base plate mounting screws. Lift out base plate and optical unit. Remove distributor shaft bearing screws.
3. On 1.5L, turn distributor shaft so flat on rotor end of distributor shaft aligns with distributor mounting flange. On all models, mark distributor shaft and gear position for reassembly. Support gear on soft wooden block and drive out roll pin. Remove gear and distributor shaft from distributor housing.

Scheme 1

Scheme 2

Reassembly & Installation

1. Coat distributor shaft with a small amount of engine oil. Assemble distributor shaft and housing. On 1.5L, turn distributor shaft so flat on rotor end of shaft aligns with distributor mounting flange.
2. On all models, assemble drive gear to distributor shaft. Align disassembly marks on distributor shaft and gear. Install NEW roll pin. To complete reassembly, reverse disassembly procedure. Ensure optical disc slots are not clogged. To install, reverse removal procedure.

CRANK ANGLE SENSOR (CAS)

Note. On 1.5L and 3.0L, optical unit containing crank angle sensor and No. 1 cylinder TDC sensor is mounted on distributor base plate. Optical unit is removed and replaced with base plate as an assembly.

Removal & Installation (1.5L & 3.0L)

See DISTRIBUTOR.

Removal & Installation (1.6L & 2.0L)

Disconnect negative battery cable. Remove 2 CAS mounting bolts. Pull CAS from cylinder head. To install, reverse removal procedure. Ensure No. 1 cylinder is at top dead center, and align punch mark on CAS housing with notch in plate.

FUEL SYSTEM

FUEL SYSTEM PRESSURE RELEASE

Disconnect fuel pump harness connector at fuel tank rear side (under rear seat on 1.6L). Start engine. After engine stalls, turn ignition switch to OFF position. Disconnect negative battery cable.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel tank cap. Remove drain plug and drain fuel from tank. Cover high pressure hose connection with shop towels to prevent fuel leakage. Disconnect high pressure hose at fuel tank. Disconnect vapor and return hoses, filler hose and fuel pump connector.
2. Support fuel tank, and remove tank support straps. Lower fuel tank, and remove fuel pump-to-fuel tank screws. Remove fuel pump support bolt on lower side of fuel tank. Remove fuel pump assembly from fuel tank.

Installation

Install fuel pump support bolt first. Use care not to pinch "O" ring. To complete installation, reverse removal procedure.

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Reconnect fuel pump harness connector. On 3.0L, remove intake manifold (plenum). On all models, disconnect high pressure fuel hose while covering fitting using shop towel. Unplug fuel injector harness. Remove fuel rail attaching bolts. Remove fuel rail with fuel injectors and pressure regulator attached. Rotate injector while pulling outward to remove from fuel rail. (Scheme 3)or (Scheme 4).

Scheme 3

Scheme 4

1. Lightly coat new injector "O" rings (fuel rail side) with fuel. Install new insulator in intake manifold. Rotate injector while pushing into fuel rail. If injector does not turn smoothly, remove injector and check "O" ring for binding.
2. Lightly coat new injector "O" rings with fuel (intake manifold side). Position fuel rail assembly over insulators. Install injectors in intake manifold. Ensure injectors rotate smoothly. If injectors do not rotate smoothly, check "O" ring for binding.
3. Bolt fuel rail assembly to intake manifold. Connect high pressure fuel hose to fuel rail. With ignition on and engine off, check for fuel leaks before starting engine. To complete installation, reverse removal procedure. See TORQUE SPECIFICATIONS table at end of article.

Removal & Installation

1. On 1.5L, 1.6L and 2.0L, O2 sensor is mounted in exhaust manifold. On 3.0L, O2 sensor is mounted downstream in exhaust pipe. O2 sensor has a permanent pigtail which must be protected from damage when removing sensor. Ensure sensor is free of contaminants. DO NOT use any cleaning solvents.
2. Ensure exhaust system is cool before removing O2 sensor, or thread damage may occur. Disconnect negative battery cable and O2 sensor connector. Remove O2 sensor.
3. To install, reverse removal procedure. Apply anti-seize compound to O2 sensor threads. Tighten to specification. See TORQUE SPECIFICATIONS table at end of article. Install negative battery cable.

1. Disconnect negative battery cable. Drain engine coolant so level is below throttle body. Disconnect accelerator cable from throttle valve lever and cable bracket.
2. Disconnect throttle position sensor connector. Label and disconnect all vacuum hoses from throttle body. Disconnect engine coolant hoses from throttle body. Remove throttle body from intake manifold.

Note. DO NOT remove throttle valve.

Cleaning & Inspection

1. Clean all components with solvent except throttle position sensor and ISC servo assembly.
2. Check for restrictions in vacuum ports and passages. Blow out using compressed air. DO NOT remove throttle valve.

Using new gasket, install throttle body on intake manifold (plenum). Tighten mounting bolts and nuts to specification. See TORQUE SPECIFICATIONS table at end of article. After installing accelerator cable, hold exposed portion of cable at center and move cable up and down to ensure slight amount of play is available. Refill cooling system.

THROTTLE POSITION SENSOR

Note. DO NOT remove throttle position sensor unless it has tested defective and is being replaced.

Note. See ADJUSTMENTS article in the ENGINE PERFORMANCE Section for throttle position sensor adjustment.

Remove air cleaner. Disconnect Throttle Position Sensor (TPS) mounting screws, and remove TPS from throttle body. To install, reverse removal procedure. Tighten TPS mounting screws to specification. See TORQUE SPECIFICATIONS table.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS