2.5L V6 Engine: Removal & Installation Hyundai Sonata IV

REMOVAL & INSTALLATION

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

Installation

To install, reverse removal procedure. Ensure cables and drive belts are properly adjusted. Replace all fluids, and check gauges for correct operation.

Removal

1. Remove air intake hose from throttle body. Remove accelerator and cruise control cables. Remove engine coolant hose.
2. Remove PCV hose and brake booster vacuum hoses. Label and disconnect vacuum hose connections. Disconnect connectors for Idle Speed Adjuster (ISA), Throttle Position (TP) sensor and Air Temperature Sensor (ATS). (Scheme 20)
3. Remove air intake surge tank bracket. Remove surge tank and gasket.

To install, reverse removal procedure. Use NEW gasket.

Scheme 20

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8278-S27113669972000081700000). Remove air intake surge tank. Remove high pressure fuel hose and return hose.
2. Remove fuel rail, with injectors and pressure regulator attached. Remove intake manifold. (Scheme 21)

Scheme 21

To install, reverse removal procedure. Use NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8278-S27113669972000081700000). Remove engine cover. Drain cooling system.
2. Remove breather hose and air intake hose. Remove vacuum, fuel and coolant hoses. Remove intake manifold. See «INTAKE MANIFOLD»(ref-8278-S21848612432000081700000). Remove plug wires from spark plugs. Remove ignition coil.
3. Remove timing belt covers, timing belt and camshaft sprockets. See «TIMING BELT»(ref-8278-S34974590102000081700000). Remove heat protector and exhaust manifold. Remove water pump and valve covers. Remove camshafts. See «CAMSHAFTS»(ref-8278-S01271718662000081700000).
4. Loosen head bolts in reverse of tightening sequence, in 2-3 steps. (Scheme 22) Remove cylinder head and gasket.

1. Install assembled cylinder head using NEW gasket, with identification mark on gasket facing cylinder head. DO NOT apply sealant to head gasket.
2. Place paint mark on cylinder head bolt for degree reference to be used during installation. Install head bolts. Tighten bolts, in 3 steps, to specification in proper sequence. (Scheme 22) At each step, reference marks on bolt head and cylinder head for proper additional tightening. See «TORQUE SPECIFICATIONS»(ref-8278-S29090053662000081700000).
3. To complete installation, reverse removal procedure. Use NEW gaskets on intake and exhaust manifolds. Adjust all control cables.

Scheme 22

1. Remove engine trim cover. Using 16 mm spanner wrench, rotate serpentine belt tension arm clockwise about 14 degrees to relieve belt tension. Remove serpentine drive belt. Remove water pump pulley, idler pulley, tensioner pulley and crankshaft pulley. Remove upper and lower timing belt covers.
2. Support engine with padded jack, and remove engine mount insulator and bracket in front of timing belt. Rotate engine clockwise to align timing mark so No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing marks line up with marks on upper surface of rocker cover. (Scheme 23) If reusing timing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt auto tensioner. Remove timing belt.

Scheme 23

1. Install idler pulley onto pin spring pressed into water pump boss. Install tensioner arm and flat washer to cylinder block. Install pulley on tensioner arm.
2. Before installing timing belt, ensure camshaft and crankshaft timing marks are aligned. (Scheme 23) If timing marks are not aligned, DO NOT turn camshaft sprockets more than 3 teeth in either direction to align (this will result in valves touching pistons).
3. Compress timing belt auto tensioner, and install set pin to hold in retracted position. Install timing belt auto tensioner to front case. Align timing marks of each sprocket and install timing belt around pulleys and sprockets in the following order: crankshaft sprocket, idler pulley, left intake cam sprocket, water pump pulley, right intake cam sprocket and tensioner pulley. (Scheme 23)
4. Pull set pin from timing belt auto tensioner to apply tension to timing belt. Adjust tension and seat timing belt by rotating crankshaft 2 complete revolutions clockwise. Check auto tension pin extended length. Extended length should be.24-.32" (6.1-8.1 mm). If length is greater than specification, belt is stretched. Install NEW timing belt. Ensure sprocket timing marks are properly aligned. If marks are not properly aligned, repeat installation procedure.
5. Install engine mount bracket and insulator. Install upper and lower timing belt covers. Install all external pulleys. Rotate auto tensioner arm about 14 degrees clockwise, and install serpentine drive belt onto pulleys. (Scheme 24) Release tensioner. Tensioner indicator mark should be between range marks. (Scheme 25) If tensioner indicator is not within range marks, replace serpentine drive belt. Install engine cover.

Scheme 24

Scheme 25

Note. Bearing caps are marked L1, L2, L3, R1, R2, R3, etc. "L" designates left side or intake camshaft. "R" designates right side or exhaust camshaft (camshaft has slots on rear end to drive position sensor). Numbers identify corresponding cam lobe. Be sure to keep bearing caps in order during removal to ensure proper reinstallation.

1. Disconnect negative battery terminal. Remove engine cover. Remove intake manifold. See «INTAKE MANIFOLD»(ref-8278-S21848612432000081700000). Drain cooling system. Remove breather hose. Remove water pump pulley, crankshaft pulley, idler pulley and tensioner pulley.
2. Remove timing belt covers. Loosen tensioner pulley, and temporarily secure in loosened position. Remove timing belt from camshaft sprockets. Remove spark plug cables. Remove valve covers. Remove camshaft sprockets.
3. Remove bearing caps, loosening in 3 steps. Remove camshafts. see scheme 9

Drain cooling system. Disconnect coolant pipe. Remove drive belt and water pump pulley. Remove timing belt covers, tensioner, idler and crankshaft sprocket. See TIMING BELT . Remove water pump mounting bolts. Remove water pump.

1. Clean mounting surfaces. Install NEW water pump gasket. Install water pump. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8278-S29090053662000081700000). Note locations of different length mounting bolts. (Scheme 26)
2. Install crankshaft sprocket, timing belt tensioner and timing belt. Install timing belt covers. Install NEW "O" ring, and connect coolant pipe.
3. Install water pump pulley and drive belt. Adjust auto tensioner. See «TIMING BELT»(ref-8278-S34974590102000081700000). Reconnect coolant hoses. Refill cooling system, and check for leaks. NOTE: For further information on cooling systems, see SPECIFICATIONS article in ENGINE COOLING.

Scheme 26

Drain engine oil. Remove oil pan retaining bolts. Using a gasket cutter, cut gasket along sealing surface of cylinder block. Remove oil pan and gasket. To install, reverse removal procedure. Apply a.16" (4.0 mm) bead of sealant to groove areas in oil pan sealing surfaces before installing. Install and tighten oil pan bolts. Tighten in PROPER sequence. see scheme 11

1. Remove timing belt. See «TIMING BELT»(ref-8278-S34974590102000081700000) under REMOVAL & INSTALLATION. Remove oil pressure switch. Remove oil filter and oil pan. Remove oil screen and gasket.
2. Remove oil filter bracket and gasket. Remove oil relief valve plug from case. Remove oil pump case. see scheme 16

Scheme 27

Reassembly & Installation

1. Apply engine oil to gears, and position in case. Install front case with NEW gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8278-S29090053662000081700000).
2. Using proper installer, install crankshaft front oil seal into front case. Install relief plug and spring. Tighten oil relief valve plug to specification. See «TORQUE SPECIFICATIONS»(ref-8278-S29090053662000081700000).
3. Install oil screen with NEW gasket. Tighten oil screen bolts. Apply sealant to groove in oil pan. Install and tighten oil pan bolts. Tighten in sequence shown. see scheme 11 See «TORQUE SPECIFICATIONS»(ref-8278-S29090053662000081700000).
4. Using pressure switch socket, install oil pressure switch after applying threadlock sealant to threads.
5. Install timing belt. See «TIMING BELT»(ref-8278-S34974590102000081700000) under REMOVAL & INSTALLATION.