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Home >> Hyundai >> 2013 >> Sonata GLS >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (Engine And Transaxle Assembly (HEV)) >> Engine And Transaxle Assembly >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.
CAUTION:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
  • Mark all wiring and hoses to avoid mis-connection.
  • To release the fuel system pressure before removing the engine assembly, start the engine with the fuel pump relay removed. And then turn off the ignition switch after engine stops.
WARNING: The hybrid system uses DC 270V high voltage. So, be sure to follow safety instructions below. Otherwise, there may be a serious injury or electrocution (Refer to "SAFETY PRECAUTION ").
  1. Shut off the High Voltage circuit (Refer to "HIGH VOLTAGE SHUTOFF PROCEDURE " ).
  2. Remove the engine cover (A).
    Fig 1: Identifying Engine Cover
    G07317327Courtesy of HYUNDAI MOTOR CO.
  3. Remove the air duct (A).

    Tightening torque: 

    7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

    Fig 2: Identifying Air Duct
    G07317328Courtesy of HYUNDAI MOTOR CO.
  4. Remove the air cleaner assembly.
    1. Disconnect the breather hose (A).
    2. Disconnect the air intake hose (B) and then remove the air cleaner assembly (C).

      Tightening torque: 

      Hose clamp bolt:

      2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)

      Air cleaner assembly bolts:

      7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

      Fig 3: Identifying Breather Hose, Air Intake Hose And Air Cleaner Assembly
      G07317329Courtesy of HYUNDAI MOTOR CO.
      NOTE:
      • When installing the air intake hose, the plate of the hose clamp must be in line with the stopper of the hose.
      • When installing the air intake hose, the center of the mark of hose must be in line with the throttle body rib.
        Fig 4: Identifying Hose And Throttle Body Centering Mark
        G07317330Courtesy of HYUNDAI MOTOR CO.
  5. Remove the under covers (A, B).

    Tightening torque: 

    7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

    Fig 5: Identifying Under Covers
    G07317331Courtesy of HYUNDAI MOTOR CO.
    NOTE: When removing the under cover (B), unfasten the mounting bracket bolts and then remove the under cover and mounting bracket assembly.
  6. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to COOLING SYSTEM )
  7. Loosen the drain plug, and drain the inverter coolant. Remove the reservoir cap to help drain the coolant faster. (Refer to "COOLANT ")
  8. Disconnect the radiator upper hose (A) and lower hose (B).
    Fig 6: Identifying Radiator Upper Hose And Lower Hose
    G07317332Courtesy of HYUNDAI MOTOR CO.
  9. Remove the HPCU (Hybrid power control unit). (Refer to "HPCU ")
  10. Remove the inverter tray (A).

    Tightening torque: 

    8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)

    Fig 7: Identifying Inverter Tray
    G07317333Courtesy of HYUNDAI MOTOR CO.
  11. Recover the refrigerant and then remove the high pressure pipe (A) and low pressure pipe (B). (Refer to "ELECTRIC A/C COMPRESSOR ")
    Fig 8: Identifying High Pressure Pipe And Low Pressure Pipe
    G07317334Courtesy of HYUNDAI MOTOR CO.
  12. Disconnect the ECM connectors (A) from the ECM, the fuse box connector (B) from the fuse/relay box and the engine ground line (C). Then remove the wiring protector (D).
    Fig 9: Identifying ECM Connectors, Fuse Box Connector, Wiring Protector And Engine Ground Line
    G07317335Courtesy of HYUNDAI MOTOR CO.
  13. Disconnect the cooling hoses from HSG (Hybrid starter generator) (A) and EWP (Electric water pump) (B).
    Fig 10: Identifying Cooling Hoses And EWP
    G07317336Courtesy of HYUNDAI MOTOR CO.
  14. Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to AUTOMATIC TRANSAXLE CONTROL SYSTEM - HEV ).
  15. Disconnect the heater hoses (A).
    Fig 11: Identifying Heater Hoses
    G07317337Courtesy of HYUNDAI MOTOR CO.
  16. Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).
    Fig 12: Identifying Fuel Hose And Purge Control Solenoid Valve Hose
    G07317338Courtesy of HYUNDAI MOTOR CO.
  17. Remove the front muffler (A).
    Fig 13: Identifying Front Muffler
    G07317339Courtesy of HYUNDAI MOTOR CO.
  18. Remove the steering u-joint mounting bolt (A). (Refer to ELECTRIC POWER STEERING - HEV )
    Fig 14: Identifying Steering U-Joint Mounting Bolt
    G07317340Courtesy of HYUNDAI MOTOR CO.
  19. Remove the front wheels. (Refer to "WHEEL ")
  20. Remove the lower arms (A). (Refer to "FRONT LOWER ARM ")
    Fig 15: Identifying Front Wheels Lower Arms
    G07317341Courtesy of HYUNDAI MOTOR CO.
  21. Remove the stabilizer bar links (A). (Refer to "FRONT STABILIZER BAR ")
    Fig 16: Identifying Stabilizer Bar Links
    G07317342Courtesy of HYUNDAI MOTOR CO.
  22. Remove the tie rod ends (A). (Refer to "STEERING GEAR BOX ")
    Fig 17: Identifying Tie Rod Ends
    G07317343Courtesy of HYUNDAI MOTOR CO.
  23. Disconnect the drive shafts (A) from the axle hubs. (Refer to "FRONT HUB/KNUCKLE ")
    Fig 18: Identifying Drive Shafts
    G07317344Courtesy of HYUNDAI MOTOR CO.
  24. Remove the roll rod bracket (A).

    Tightening torque: 

    Bolt (B):

    107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)

    Bolt (C):

    49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

    Fig 19: Identifying Roll Rod Bracket
    G07317345Courtesy of HYUNDAI MOTOR CO.
  25. Remove the roll rod mounting support bracket (A).

    Tightening torque: 

    49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

    Fig 20: Identifying Roll Rod Mounting Support Bracket
    G07317346Courtesy of HYUNDAI MOTOR CO.
  26. Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts. (Refer to "FRONT CROSS MEMBER ")

    Tightening torque: 

    Sub frame mounting bolts & nuts:

    156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)

    Stay mounting bolts:

    44.1 ~ 58.8 N.m (4.5 ~ 6.0 kgf.m, 32.5 ~ 43.4 lb-ft)

    Fig 21: Identifying Sub Frame Mounting Bolts And Nuts
    G07317347Courtesy of HYUNDAI MOTOR CO.
    NOTE:
    • After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall downward, and so support them securely with floor jack.
    • Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
  27. Support the engine and transaxle assembly with a floor jack, and then disconnect the ground line (A) and remove the engine mounting support bracket (B).

    Tightening torque: 

    78.4 ~ 98.0 N.m (8.0 ~ 10.0 kgf.m, 57.6 ~ 72.0 lb-ft)

    Fig 22: Identifying Ground Line And Engine Mounting Support Bracket
    G07317348Courtesy of HYUNDAI MOTOR CO.
  28. Disconnect the ground line (A).
    Fig 23: Identifying Ground Line
    G07317349Courtesy of HYUNDAI MOTOR CO.
  29. Remove the automatic transaxle support bracket mounting bolt (B) after removing the cover (A).

    Tightening torque: 

    88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

    Fig 24: Identifying Cover
    G07317350Courtesy of HYUNDAI MOTOR CO.
    Fig 25: Identifying Automatic Transaxle Support Bracket Mounting Bolt
    G07317351Courtesy of HYUNDAI MOTOR CO.
  30. Lower floor jack with the engine and transaxle assembly, and then remove the engine and transaxle assembly by lifting vehicle.
    Fig 26: Removing Engine And Transaxle Assembly
    G07317352Courtesy of HYUNDAI MOTOR CO.
    CAUTION: When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
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