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

Testing & Diagnostics 10 illustrations ~856 words

Removal

Note. When replacing the ECM, the vehicle equipped with immobilizer must be performed the procedure as below. [In the case of installing used ECM] Perform "Neutral mode" procedure with GDS. (Refer to IMMOBILIZER SYSTEM in BE group) Insert the key and turn it to the IGN ON and OFF position. Then the ECM key register process is completed automatically. [In the case of installing new ECM] Insert the key and turn it to the IGN ON and OFF position. Then the ECM key register process is completed automatically.

Scheme 124

Scheme 124: Removal
Scheme 124: Removal

Scheme 125

Scheme 125
Scheme 125

Scheme 126

Scheme 126
Scheme 126
  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-419405) " in EM group).
  4. Remove the mounting bolts (A)/nut (B), and then remove the ECM (C).

Installation

Note. When replacing the ECM, the vehicle equipped with immobilizer must be performed the procedure as below. [In the case of installing used ECM] Perform "Neutral mode" procedure with GDS. (Refer to IMMOBILIZER SYSTEM in BE group) Insert the key and turn it to the IGN ON and OFF position. Then the ECM key register process is completed automatically. [In the case of installing new ECM] Insert the key and turn it to the IGN ON and OFF position. Then the ECM key register process is completed automatically.

  1. Installation is reverse of removal. ECM installation bolt: 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)
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
  1. Installation is reverse of removal. Electronic throttle body Installation bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
  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)

CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine coolant to the O-ring.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
  1. Installation is reverse of removal.
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine oil to the O-ring.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
  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)

WARNINGDON'T remove the camshaft position sensor during engine running or right after engine stops, or a scald by the flowed out engine oil may occur.

Scheme 127

Scheme 127: [Bank 1 / Intake]
Scheme 127: [Bank 1 / Intake]
  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.

Scheme 128

Scheme 128: [Bank 1 / Exhaust]
Scheme 128: [Bank 1 / Exhaust]
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Disconnect the camshaft position sensor connector (A).
  3. Remove the hanger and the protector.
  4. Remove the installation bolt (B), and then remove the sensor.
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine oil to the O-ring.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
CAUTIONBe careful not to damage the sensor housing and the connector. Be careful not to damage the O-ring.
  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)

CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
  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)

CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONDON'T use a cleaner, spray, or grease to sensing element and connector of the sensor because oil component in them may malfunction the sensor performance. Sensor and its wiring may be damaged in case of contacting with the exhaust system (Exhaust Manifold, Catalytic Converter, and so on).
  1. Installation is reverse of removal.

Heated oxygen sensor installation : 39.2 ~ 49.1 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)

CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine oil to the injector O-ring.
CAUTIONInspect the injector O-ring when installing.
  1. Installation is reverse of removal.

Delivery pipe installation bolt: 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

Delivery pipe installation nut (<--> Fuel feed tube): 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

CAUTIONInstall 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.
CAUTIONUse care to keep foreign material out of the valve.
CAUTIONInstall the purge control solenoid valve after lifting the support pin (A) of the bracket.

Scheme 129

Scheme 129
Scheme 129
  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)

  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.

[Bank 1 / Intake]

Scheme 130

Scheme 130
Scheme 130

[Bank 1 / Exhaust]

Scheme 131

Scheme 131
Scheme 131
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine oil to the valve O-ring.
  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)

  1. Install the component with the specified torques.
  2. Note that internal damage may occur when the component is dropped.

If the component has been dropped, inspect before installing.

  1. Installation is reverse of removal.

NVLD installation bolt: 2.3 ~ 3.3 N.m (0.2 ~ 0.3 kgf.m, 1.7 ~ 2.5 lb-ft)

Scheme 132

Scheme 132: [Mechanical inspection]
Scheme 132: [Mechanical inspection]
  1. Turn ignition switch OFF.
  2. Disconnect the NVLD connector.
  3. Remove the NVLD.
  4. Connect the hose (A) to the canister hose connected port as below.
  5. After immersing the hose (A) in water, Apply more than 6 mbar (positive) pressure to Atmosphere port (B).
  6. If the NVLD is normal, many bubbles will indicate large leak. NOTE: Allowable internal leakage of 0.35 g/hr at 3 mbar will show as one bubble every second (approximately).

Scheme 133

Scheme 133: [Electrical inspection]
Scheme 133: [Electrical inspection]
  1. Connect power supply line and ground line to the NVLD terminals as below.
  2. Measure current between the NVLD terminal 1 and battery (+) terminal during NVLD switch open.
  3. Measure current between the NVLD terminal 1 and battery (+) terminal during NVLD switch closed.
  4. Measure current between the NVLD terminal 2 and battery (+) terminal during NVLD switch open.
  5. Check the current is within the specification. NOTE: NVLD switch is normal open. When applying more than 6 mbar (Positive) pressure to canister port, switch is closed.

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