Monday, March 14, 2011

how to replace spark plugs and spark plug wires on 2001 Hyundai Sonata?


1. Get a service/repair manual before you start any of your own work on your vehicle. It will pay for itself over and over again. If you dont have manual no issue.This is the procedure.

2. Make sure your motor is off and cool before you start.

3. Take just one spark plug wire off one plug by grabbing the spark plug wire boot and not the wire itself. Or use a spark plug wire puller.

4. Make sure there is no dirt and/or oil around the spark plug. If needed, wipe the area around the spark plug hole being careful not to brush the dirt and oil away from the hole. Better yet blown it out with compressed air if you have a compressor.

5. Take out that plug with the proper tools by turning the plug to the left (counter clockwise). Usually the tool is a 13/16 or 5/8 deep socket. You may have to have a swivel joint and an extension also.

6. Apply anti-seize compound to the plug threads. Replace it with a new one turning the spark plug in by hand until hand tight.

7. Use the same tool you used to take out the old plug to snug up the new plug. Do not over tighten.

8. Connect the spark plug wire onto the new plug. Make sure it is on. They usually kind of snap on.

9. Follow steps three through eight until all spark plugs have been replaced.

Tips: While you are at the parts store you might want to get a spark plug gaper and spark plug wire puller. Even though the gap is pre set on new plugs it is a very good idea to check it (ask the counter clerk at the auto parts store for the recommended gap). The wire puller saves the wires from pulling apart from the boot. Doing just one plug at a time helps you to keep everything in order. A crossed plug wire means the vehicle will miss fire or fire out of order. Take a good look at the old plugs. They can tell you a lot on how your vehicle is running. While you are under the hood, consider spending another $20 - $30 for high quality plug wires. If you replace the plug wires be very careful and only do them one at a time and don't get them crossed. What You Need: Socket Driver 3/16 or 5/8 deep socket 3" and 6" drive extensions Swivel adapter for the driver allows for tight spaces Anti-seize compound



Inspection



2.4L Engine
  1. Remove engine cover.
  2. Remove the spark plug cable (A).
    NOTE
    When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be damaged.

  3. Using a spark plug socket, remove the spark plug (B).
    CAUTION
    Be careful that no contaminants enter through the spark plug hole.

  4. Inspect the electrodes (A) and ceramic insulator (B).

    Click image to see an enlarged view

    Fig. Spark Plug detail


2.7L & 3.5L Engine
  1. Remove the engine cover.
  2. Disconnect the VIS actuator connectors and injector connectors.
  3. Remove the accelerator cable.
  4. Remove surge tank sub assembly.
  5. Remove the spark plug cable.
  6. Remove the spark plug.
  7. Inspect the electrodes and ceramic insulator.

    Click image to see an enlarged view

    Fig. Electrode inspection analysis chart

  8. Check the electrode gap.
    1. Standard Gap (New)
    2. 1.0-1.1 mm (0.039-0.043 in.)-Unleaded


Except 2.4L, 2.7L & 3.5L
  1. Remove engine cover.
  2. Remove the spark plug cable (A).
    NOTE
    When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be damaged.

  3. Using a spark plug socket, remove the spark plug (B).
    CAUTION
    Be careful that no contaminants enter through the spark plug hole.

  4. Inspect the electrodes (A) and ceramic insulator (B).

    Click image to see an enlarged view

    Fig. Spark Plug detail


Removal & Installation



2.7L & 3.5L Engine
  1. Remove the engine cover.
  2. Disconnect the Variable Intake System (VIS) actuator connectors and the fuel injector connectors.
  3. Remove the accelerator cable.
  4. Remove surge tank sub assembly.
  5. Remove the spark plug cable.
  6. Remove the spark plug.
  7. Check the electrode gap of the new spark plugs.
    1. Standard (New)
    2. 1.0-1.1 mm (0.039-0.043 in.)-Unleaded

  8. To install, reverse the removal procedure. Tighten the spark plugs to 11 ft. lbs. (15 Nm).

Except 2.7L & 3.5L
  1. Remove the spark plug cables.
    NOTE
    When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be damaged.

  2. Using a spark plug socket, remove the spark plugs.
    CAUTION
    Be careful that no contaminants enter through the spark plug holes.

    1. Check the electrode gap of the new spark plugs.
    2. Standard (New)
    3. 1.0-1.1 mm (0.039-0.043 in.)-Unleaded

  3. To install, reverse the removal procedure. Tighten the spark plugs to 11 ft. lbs. (15 Nm).


How to remove starter and starter relay:-----
  1. Remove fuse box cover.
  2. Remove the starter relay (A).

    Click image to see an enlarged view

    Fig. Starter relay position in the fuse box.

  3. Install new starter relay.
  4. Replace fuse box cover.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Negative battery cable
    Speedometer and shift control cables
    Starter electrical connectors
    Starter motor



  3. Click image to see an enlarged view

    Fig. Exploded view of the starter-XG 300 and XG 350


To install:

  1. Install or connect the following:

    Starter motor and torque the bolts to 25 ft. lbs. (34 Nm)
    Starter electrical connectors
    Speedometer and shift control cables
    Negative battery cable


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:

    Negative battery cable
    Air intake assembly
    Speedometer cable
    Shift cable
    Starter wiring connectors
    Starter motor


To install:

  1. Install or connect the following:

    Starter motor and torque the bolts to 20-25 ft. lbs. (26-33 Nm)
    Starter wiring connectors and torque the battery cable nut to 88-140 inch lbs. (10-16 Nm)
    Shift cable
    Speedometer cable
    Air intake assembly
    Negative battery cable


  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Negative battery cable
    Air intake assembly
    Speedometer cable
    Shift cable
    Starter wiring connectors
    Starter motor


To install:

  1. Install or connect the following:

    Starter motor and torque the bolts to 20-25 ft. lbs. (26-33 Nm)
    Starter wiring connectors and torque the battery cable nut to 88-140 inch lbs. (10-16 Nm)
    Shift cable
    Speedometer cable
    Air intake assembly
    Negative battery cable


  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Negative battery cable
    Speedometer and shift control cables
    Starter electrical connectors
    Starter motor


To install:

  1. Install or connect the following:

    Starter motor and torque the bolts to 25 ft. lbs. (34 Nm)
    Starter electrical connectors
    Speedometer and shift control cables
    Negative battery cable.


All Others
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Negative battery cable and wait at least 3 minutes
    Speedometer cable and shift cable from the transaxle
    Starter motor wiring
    Starter motor bolts and the starter


To install:

  1. Installation is the reverse of removal. Tighten motor retainers to 20-25 ft. lbs. (27-34 Nm).

Testing & Troubleshooting




NOTE
The battery must be in good condition and fully charged.

  1. Remove the fuel pump relay(A) from the fuse box.

    Click image to see an enlarged view

    Fig. Fuel pump relay location

  2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to "START" If the starter normally cranks the engine, starting system is OK.
  3. If the starter will not crank the engine at all, go to next step.
  4. If it won't disengage from the ring gear when you release key, check for the following until you find the cause:

    Solenoid plunger and switch malfunction.
    Dirty pinion gear or damaged overrunning clutch.


Check the battery condition. Check electrical connections at the battery, battery negative cable connected to the body, engine ground cables, and the starter for looseness and corrosion. Then try starting the engine again. If the starter cranks normally the engine, repairing the loose connection repaired the problem. The starting system is now OK.

  1. If the starter still does not crank the engine, go to next step.

Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of solenoid to the S-terminal of solenoid. If the starter cranks the engine, go to next step. If the starter still does not crank the engine, remove the starter, and repair or replace as necessary.

  1. Check the following items in the order listed until you find the open circuit.

    Check the wire and connectors between the driver's under-dash fuse/relay box and the ignition switch, and between the driver's under-dash fuse/relay box and the starter.
    Check the ignition switch.
    Check the transaxle range switch connector or ignition lock switch connector.
    Inspect the starter relay.


Free Running Test
  1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows.
  2. Connect a test ammeter (100-ampere scale) and carbon pile rheostats as shown in the illustration.
  3. Connect a voltmeter (15-volt scale) across starter motor.

    Click image to see an enlarged view

    Fig. Starter free-running test

  4. Rotate carbon pile to the off position.
  5. Connect the battery cable from battery's negative post to the starter motor body.
  6. Adjust until battery voltage shown on the voltmeter reads 11volts.
  7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.
  8. Current : 85A MAX Speed : 2,600 rpm MIN.


Ignition timing and adjustments:---

These engines are equipped with a Distributorless Ignition System (DIS). No adjustment is necessary.

1.8L & 3.0L (VIN T) Engines




NOTE
Timing is adjusted with the engine at normal operating temperature and all electrical accessories OFF.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Start the engine and allow it to reach operating temperature.
  3. Turn the engine OFF .
  4. Ground the ignition timing terminal.

    Click image to see an enlarged view

    Fig. Connect the jumper wire from ground to the ignition timing terminal-3.0L engine



    Click image to see an enlarged view

    Fig. Connect the jumper wire from ground to the ignition timing terminal-1.8L engines

  5. Connect a timing light to the No. 1 spark plug wire.
  6. Start the engine and check the base timing. Base timing should be 3-7 degrees Before Top Dead Center (BTDC).
  7. Adjust the timing as necessary.
  8. Turn the engine OFF .
  9. Remove the ignition timing connector ground wire and the timing light.


NOTE
Timing is adjusted with the engine at normal operating temperature and all electrical accessories OFF.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Start the engine and allow it to reach operating temperature.
  3. Turn the engine OFF .
  4. Ground the ignition timing terminal.

    Click image to see an enlarged view

    Fig. Connect the jumper wire from ground to the ignition timing terminal-3.0L engine



    Click image to see an enlarged view

    Fig. Connect the jumper wire from ground to the ignition timing terminal-1.8L engines

  5. Connect a timing light to the No. 1 spark plug wire.
  6. Start the engine and check the base timing. Base timing should be 3-7 degrees Before Top Dead Center (BTDC).
  7. Adjust the timing as necessary.
  8. Turn the engine OFF .
  9. Remove the ignition timing connector ground wire and the timing light.

Except 1.8L And 3.0L (VIN T) Engines



These engines are equipped with a Distributorless Ignition System (DIS). No adjustment is necessary.

These engines are equipped with a Distributorless Ignition System (DIS). No adjustment is necessary.


The ignition timing is controlled by the Powertrain Control Module (PCM). No adjustment is necessary or possible.



With distributor engine adjustments:----

All engines except the 3.0L and 3.5L (VIN T) V6 are equipped with a Distributorless Ignition System (DIS).

All engines except the 3.0L (VIN T) V6 are equipped with a Distributorless Ignition System (DIS).

Installation



Timing Disturbed
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Set the crankshaft to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder.
  3. Align the timing marks on the distributor gear and the distributor housing.
  4. Install the distributor by aligning the groove of the installation flange with the center of the installation stud.
  5. Connect the distributor electrical connectors.
  6. Install the distributor cap.
  7. Check the ignition timing and adjust as necessary.

    Click image to see an enlarged view

    Fig. Aligning the distributor housing and gear mating marks-3.0L Sonata


Timing Not Disturbed
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Install the distributor with the rotor-to-housing and the housing-to-engine matchmarks aligned.
  3. Install the distributor electrical connectors.
  4. Install the distributor cap.
  5. Check the ignition timing and adjust as necessary.

Removal



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove the distributor cap.
  3. Remove the distributor electrical connectors.
  4. Matchmark the rotor to the distributor housing.
  5. Matchmark the distributor housing to the engine.
  6. Unbolt and remove the distributor.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Distributor cap
    Distributor electrical connectors

  3. Matchmark the rotor to the distributor housing.
  4. Matchmark the distributor housing to the engine.
  5. Unbolt and remove the distributor.

Timing Disturbed
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Set the crankshaft to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder.
  3. Align the timing marks on the distributor gear and the distributor housing.
  4. Install or connect the following:

    Distributor, by aligning the groove of the installation flange with the center of the installation stud
    Distributor electrical connectors
    Distributor cap

  5. Check the ignition timing and adjust as necessary.

Timing Not Disturbed
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Install or connect the following:

    Distributor, with the rotor-to-housing and the housing-to-engine matchmarks aligned
    Distributor electrical connectors
    Distributor cap

  3. Check the ignition timing and adjust as necessary.


Distributor-less engine adjustments:----


These engines are equipped with a Distributorless Ignition System (DIS). No adjustment is necessary.

-------------


Firing order for various engine models:------






Click image to see an enlarged view

Fig. 2.4L and 1.5L DOHC engine Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. 1.5L SOHC, Sonata 2.0L engines Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. Elantra and Tiburon with 2.0L engines Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. 2.5L and 2.7L engine Firing order: 1-2-3-4-5-6 Distributorless ignition system



Click image to see an enlarged view

Fig. 3.0L and 3.5L engine Firing order: 1-2-3-4-5-6 Distributor rotation: Clockwise



Click image to see an enlarged view

Fig. 2.4L and 1.5L DOHC engine Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. 1.5L SOHC, Sonata 2.0L engines Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. Elantra and Tiburon with 1.8L and 2.0L engines Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. 2.5L engine Firing order: 1-2-3-4-5-6 Distributorless ignition system



Click image to see an enlarged view

Fig. 3.0L engine Firing order: 1-2-3-4-5-6 Distributor rotation: Clockwise



Click image to see an enlarged view

Fig. 2.4L engine Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. 1.5L SOHC, Sonata 2.0L engines Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. Elantra and Tiburon with 2.0L engines Firing order: 1-3-4-2 Distributorless ignition system



Click image to see an enlarged view

Fig. 2.5L and 2.7L engine Firing order: 1-2-3-4-5-6 Distributorless ignition system