Engine Control System - 2.0L - Except Hev: Removal & Installation Hyundai Sonata VI

Removal

Scheme 438

Scheme 439

Scheme 440

1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the ECM Connector (A).
3. Remove the air cleaner assembly (Refer to " «INTAKE AND EXHAUST SYSTEM»(ref-424823) " ).
4. Remove the mounting bolts (A) and nut (B), and then remove the ECM assembly (C).
5. Remove the installation nuts (A) and screw (B), and then remove the ECM (C) from the bracket.

Installation

1. Installation is reverse of removal. ECM installation nut: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) ECM bracket installation bolt/nut: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

1. Installation is reverse of removal. Electronic throttle body Installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

1. Installation is reverse of removal. Manifold absolute pressure sensor installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

1. Installation is reverse of removal.

1. Installation is reverse of removal. Crankshaft position sensor installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) Crankshaft position sensor protector installation bolt (M6): 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) Crankshaft position sensor protector installation bolt (M8): 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

[Bank 1/Intake]

Scheme 441

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Disconnect the camshaft position sensor connector (A).
3. Remove the installation bolt (B), and then remove the sensor.

[Bank 1/Exhaust]

Scheme 442

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Remove the heater protect cover (Refer to " «INTAKE AND EXHAUST SYSTEM»(ref-424823) " ).
3. Disconnect the camshaft position sensor connector (A).
4. Remove the hanger and the protector.
5. Remove the installation bolt, and then remove the sensor.

1. Installation is reverse of removal. Camshaft position sensor installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

1. Installation is reverse of removal. Knock sensor installation bolt: 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

1. Installation is reverse of removal. Heated oxygen sensor installation (Bank 1/Sensor 1): 39.2 ~ 49.1 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft) Heated oxygen sensor installation (Bank 1/Sensor 2): 35 ~ 45 N.m (3.6 ~ 4.6 kgf.m, 25.8 ~ 33.2 lb-ft)

1. Installation is reverse of removal. Rail Pressure Sensor Installation: 18.0 ~ 22.0 N.m (1.8 ~ 2.2 kgf.m, 13.3 ~ 16.2 lb-ft)

1. Installation is reverse of removal.

Refer to " ACCELERATOR PEDAL "

Refer to " ACCELERATOR PEDAL "

1. Installation is reverse of removal.

Scheme 443

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Release the residual pressure in fuel line (Refer to " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(ref-424831-S30652370042011100100000) " ). CAUTION: When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of "Release Residual Pressure in Fuel Line" work.
3. Remove the delivery pipe & injector assembly (Refer to " «DELIVERY PIPE»(ref-424831-S17178466752011100100000) " ).
4. Remove the fixing clip (A), and then separate the injector from the delivery pipe.

Scheme 444

Scheme 445

Scheme 446

1. Combustion seal
2. Rubber washer
3. Support disc
4. O-ring CAUTION: Do not reuse the used injector fixing clip. CAUTION: Install the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing. CAUTION: Apply engine oil to the injector O-ring. Do not reuse the used injector O-ring. CAUTION: Do not reuse the used bolt. CAUTION: When inserting the injector, be careful not to damage the injector tip. CAUTION: Do not reuse the support disc. Do not reuse the injector rubber washer. When replacing the rubber washer, the steal plate (A) part should be faced the cylinder installation part and the rubber plate (B) part should be faced the injector body part. CAUTION: Do not reuse the combustion seal. CAUTION: When tightening the delivery pipe installation bolts, tighten them in accordance with the order ((1) --> (2) --> (3)) after tightening with hand-screwed torque.

1. Installation is reverse of removal.

Replacement

The injector combustion seal should be replaced new one to prevent leakage after removing the injector.

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

1. Remove the combustion seal (A) with a wire cutter. CAUTION: Grip the sealing ring carefully, pull it to form a small loop and then cut it. Be careful not to damage the surface of the valve sleeve with the wire cutter.
2. Before the assembly of the sealing ring the groove must be cleaned using a clean cloth. Any coking of the injector sealing surface must be carefully removed with a brass-wire brush. CAUTION: The surfaces of the new sealing ring must be clean and free of grease.
3. Place the seal installing guide (B) (SST No.: 09353-2B000) on the tip of the injector not to damage the injector tip (A). Push the sealing ring (C) with thumb and index finger over the conical assembly tool until it snaps into the groove. The complete assembly must not take longer than 2 to 3 seconds.
4. To size the sealing ring the injector is first introduced into the sizing tool (A) (SST No.: 09353-2B000) and then pressed and at the same time rotated 180° into the sizing tool.
5. Pull the injector out of the sizing tool by turning it in the reverse direction to that used for the press-in process. CAUTION: Check that the seal ring has not been damaged during assembly to the injector and that no circumferential scratches are present. Do not reuse the combustion seal. The seal must be completely free of grease and oil.
6. Check the combustion seal (A) installation.

Scheme 453

1. Installation is reverse of removal. Purge control solenoid valve bracket installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

[Bank 1/Intake]

Scheme 454

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Remove the OTS (A).
3. Disconnect the CVVT oil control valve connector (B).
4. Remove the installation bolt (C), and then remove the valve from the engine.

[Bank 1/Exhaust]

Scheme 455

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Disconnect the CVVT oil control valve connector (A).
3. Remove the installation bolt (B), and then remove the valve from the engine.

1. Installation is reverse of removal. CVVT oil control valve installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Refer to " HIGH PRESSURE FUEL PUMP " .

Refer to " HIGH PRESSURE FUEL PUMP " .

1. Installation is the reverse order of removal.

Scheme 456

1. Turn ignition switch OFF.
2. Connect a GDS Data Link Connector (DLC).
3. Turn ignition switch ON.
4. Select "Current data".
5. Loosen the rod end lock nut (A) remove the C-ring (B).
6. Adjust the rod end part (C) by rotating it at the direction of clockwise or counter clockwise to satisfy the specification. If output voltage > 4.2 : Clockwise (D) If output voltage < 4.2 : Counter Clockwise (E) Specification: 4.2 ± 0.1V
7. Check output voltage on current data in GDS after installing the rod end part (C) without the clip. If output voltage satisfy the specification, fix the rod end part with clip.

1. Installation is the reverse order of removal.

1. Installation is reverse of removal.