3.0 V6 Engine: Removal & Installation Hyundai Sonata III рестайлинг

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49498-S27404767522001011500000) . Label and disconnect fuel lines and vapor hoses from engine. Drain cooling system, engine oil and transaxle oil. Remove battery.
2. Disconnect electrical connectors from oxygen sensor, A/C compressor, back-up light switch, generator and oil pressure switch. Disconnect throttle cables. Disconnect power steering pump, leaving hoses attached and wire aside. Disconnect speedometer cable from transaxle.
3. Label, disconnect and plug transaxle cooler lines. Remove upper and lower radiator hoses from engine. Remove radiator assembly with hoses. Disconnect heater hoses at engine side. Disconnect transaxle control cable from transaxle. Disconnect all wires from distributor. Disconnect engine ground. Disconnect brake booster vacuum hose. Detach A/C compressor from mounting bracket, and wire aside.
4. Raise and support vehicle. Remove oil pan shield. Disconnect front exhaust pipe at manifold and suspend pipe from bottom of vehicle with wire. Remove lower ball joint bolts and stabilizer bar where bar is mounted to lower control arm. Remove axle shafts from transaxle. Hang lower control arms and axle shafts from body with wire. Plug holes in transaxle to prevent contamination. NOTE: Replace axle shaft retainer rings whenever axle shafts are removed from transaxle.
5. Attach engine hoist to engine, and raise engine just enough to relieve load on engine mounts. Remove front roll stopper, damper and rear roll stopper. Remove engine mount bolts. Remove bolts and nuts securing engine mount bracket to body. Raise engine a few inches. NOTE: Ensure all cables, hoses, harnesses, connectors, etc. are disconnected from engine.
6. Remove blind plugs from inside right front fender apron. Remove transaxle mounting bracket bolts. Remove left mount insulator bolt. Direct transaxle side downward and lift assembly out of vehicle.

Installation

To install, reverse removal procedure. Ensure throttle, transaxle cables and drive belts are properly adjusted. Tighten mounting bolts and nuts to specification with weight of engine on mounts. See TORQUE SPECIFICATIONS . Replace all fluids and check gauges for correct operation.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49498-S27404767522001011500000) . Drain cooling system. Label and disconnect all wiring, hoses, cables and brackets interfering with intake plenum and manifold removal.
2. Remove intake plenum. Remove fuel rail with injectors attached. Remove intake manifold-to-cylinder head attaching bolts and remove intake manifold. To install, reverse removal procedure. Use NEW gaskets.

1. Disconnect negative battery cable. Label and disconnect all wiring, hoses, cables and brackets interfering with exhaust manifold removal. Remove exhaust manifold heat shield.
2. Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold-to-cylinder head attaching bolts and exhaust manifold. To install, reverse removal procedure. Use NEW gaskets.

1. Drain cooling system. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49498-S27404767522001011500000). Remove timing belt cover.
2. Turn crankshaft so piston No. 1 is on TDC of compression stroke. Align marks on upper inner cover with mark on camshaft sprockets. (Scheme 23) Mark timing belt at timing mark on camshaft sprockets for reassembly.
3. Remove camshaft sprocket retaining bolt. Slide camshaft sprocket (with belt attached) off camshaft. DO NOT turn crankshaft. Ensure belt remains engaged with crankshaft. Remove distributor cap. Reference mark rotor to distributor position. Reference mark distributor to adapter position. Remove distributor and adapter.
4. Remove valve cover. Loosen rocker arm retaining bolts in 2 or 3 passes. Using Lash Adjuster Retainer (09246-32000), secure lash adjusters. (Scheme 24) Remove rocker arm assembly and camshaft. See «ROCKER ARM SHAFT ASSEMBLY»(ref-49498-S08469614402001011500000).
5. Label and disconnect wiring, hoses, linkages, cables and brackets interfering with cylinder head removal. Disconnect exhaust pipe. Remove intake air plenum and manifold. Loosen cylinder head bolts in 2 stages using proper sequence. (Scheme 25)
6. Remove cylinder head bolts. Remove cylinder head with exhaust manifold attached. Remove exhaust manifold from cylinder head (if necessary).

Scheme 23

Scheme 24

Scheme 25

1. Install cylinder head using NEW gasket. Tighten cylinder head bolts in proper sequence. (Scheme 26)
2. Carefully remove Lash Adjuster Retainers (09246-32000). DO NOT allow lash adjusters to fall out. Tighten rocker shaft mounting bolts uniformly to 14-15 ft. lbs. (19-21 N.m). To complete installation, reverse removal procedure.

Scheme 26

1. Align camshaft and crankshaft timing marks. (Scheme 23) Install timing belt on crankshaft sprocket, and then rear camshaft sprocket. Position timing belt under water pump pulley, over front camshaft sprocket and then over tensioner pulley.
2. Apply force counterclockwise to rear camshaft sprocket, applying tension to tight side of belt. Ensure timing marks are aligned. Loosen tensioner bolt allowing tensioner to take up slack in timing belt. Tighten tensioner bolt temporarily. Rotate crankshaft 2 turns clockwise.
3. Realign timing marks. Loosen tensioner bolt, allowing tensioner to take up timing belt slack. Tighten tensioner bolt. Measure timing belt tension using belt tension gauge. For new belt, tension should be 57-84 lbs. (26-38 kg).
4. Install crankshaft pulley and tighten to specification. To complete installation, reverse removal procedure. Tighten engine support bracket bolts in sequence shown. (Scheme 25) Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49498-S33260421342001011500000).

1. Remove upper timing belt cover. Turn crankshaft so No. 1 piston is at TDC of compression stroke. Align timing marks on upper inner cover with mark on camshaft sprockets. (Scheme 23)
2. Make reassembly reference mark on timing belt in alignment with timing mark on camshaft sprockets. Remove camshaft sprocket retaining bolt. Slide camshaft sprocket (with belt attached) off camshaft. DO NOT turn crankshaft. Prevent belt from disengaging from crankshaft sprocket. Remove distributor cap. Reference mark rotor to distributor. Reference mark distributor to adapter. Remove distributor and adapter.
3. Remove rocker cover. Loosen rocker arm retaining bolts in 2 or 3 passes. Using Lash Adjuster Retainer (09246-32000), secure lash adjusters. (Scheme 24) Remove rocker arm assembly and camshaft.

1. Lubricate bearing journals and lobes of camshaft. Install camshaft into cylinder head. Using Lash Adjuster Retainers (09246-32000), prevent adjusters from falling out, insert lash adjusters into cam followers.
2. Apply a minimum amount of sealer to outside corners of front and rear camshaft bearing caps. Install rocker arm assembly to cylinder head so arrow mark on bearing caps face the same way as arrow mark on cylinder head. Tighten bearing cap bolts to 14-15 ft. lbs. (19-21 N.m). Remove Lash Adjuster Retainer (09246-32000) from lash adjuster. To complete installation, reverse removal procedure.

Remove transaxle. See appropriate article in CLUTCHES (M/T) or TRANSMISSION REMOVAL & INSTALLATION article (A/T) in TRANSMISSION SERVICING. Remove flexplate/drive plate. Remove rear main oil seal case and gasket from rear of cylinder block. Remove oil separator and oil seal from seal case.

1. To install, coat seal lip with oil. Using Seal Installer (09231-33000), install seal in seal case until it bottoms.
2. Install oil separator in seal case with hole of separator at bottom of seal case. Install seal case and gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49498-S33260421342001011500000) . Install flexplate. Tighten bolts to specification. To complete installation, reverse removal procedure.

Scheme 27

Drain cooling system and disconnect battery. Remove necessary coolant hoses. Remove timing belt. See TIMING BELT . Remove pump mounting bolts. Note bolt length and location for reassembly reference. Remove generator brace and water pump.

To install, reverse removal procedure. Use NEW gasket and "O" ring. Install "O" ring on coolant pipe, and apply water to "O" ring. DO NOT apply grease or oil to "O" ring. Ensure bolts are installed in original location.

Drain engine oil. Remove oil pan retaining bolts. Using gasket cutter, cut gasket along sealing surface of cylinder block. Remove oil pan and gasket. To install, clean gasket surfaces and apply sealant into groove of oil pan. To complete installation, reverse removal procedure.

Piston Pin Replacement

Piston location must be noted before removing piston from connecting rod. Piston pin fit in connecting rod requires use of proper force during installation. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS.

Remove timing belt and crankshaft sprocket. See TIMING BELT under REMOVAL & INSTALLATION. Remove oil filter, oil pan and oil screen. Remove oil filter bracket. Remove front cover and oil pump assembly.

Reassembly & Installation

1. Using Installer (09214-33000), install NEW seal into front cover. Install front cover using NEW gasket. Install oil filter bracket. Install proper length bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-49498-S33260421342001011500000). (Scheme 28)
2. Using plug cap wrench, install plug cap and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-49498-S33260421342001011500000). To install remaining components, reverse removal procedure.

Scheme 28