Engine - Turbocharger Oil Feed Pipe Replacement
Group ENGINENumber 10-EM-004
Date OCTOBER, 2010
Model 2011 SONATA 2.0T
Subject:
TURBOCHARGER OIL FEED PIPE REPLACEMENT PROCEDURE
DESCRIPTION:
This bulletin provides the procedure to replace the turbocharger oil feed pipe.
APPLICABLE VEHICLES:
^ 2011 (YF) Sonata 2.0L Turbo vehicles
REQUIRED TOOLS
PARTS INFORMATION
SERVICE PROCEDURE:
1. Secure the vehicle on a lift.
^ Ensure that the vehicle is properly positioned on the lift.
^ Lifting points should not contact any exterior body parts such as the rocker panel.
2. Rotate the steering wheel fully to the left to create more working clearance for later steps.
3. Remove the engine cover by firmly lifting up at the corners.
4. Remove the (1) 10 mm 02 sensor connector bracket bolt from the cylinder head and move the bracket slightly away from the exhaust manifold.
5. Carefully remove the exhaust manifold heat shield.
^ Remove the (3) 10 mm exhaust heat shield bolts and set aside for reuse.
^ Remove the heat shield and set aside for reuse.
NOTE:
During removal of the heat shield, some flexing of the part may be required. However, do not deform the heat shield by creasing or folding it.
6. Locate the oil feed pipe connection point at the turbocharger.
7. Remove the (1) 17 mm banjo bolt and (2) copper sealing washers.
^ Retain the banjo bolt for later reuse.
^ Retain the (2) copper sealing washers for later reuse.
8. Lift the vehicle to a suitable height for under vehicle work.
9. Remove the (2) plastic screws, (5) metal screws, (3) short 10 mm bolts, and (3) long 10 mm bolts retaining the under covers (A) and (B).
^ Carefully lower and set aside the (3) under cover sections away from the work area for later reinstallation.
10. Locate the oil feed pipe connection point at the engine block.
11. Place a shop towel under the connection flange to capture any residual oil that may drain from the cylinder block during oil pipe disconnection.
12. Remove the (2) 10 mm nuts retaining the oil feed pipe to the cylinder block.
^ Retain the (2) 10 mm nuts for reuse.
13. Carefully remove the oil feed pipe.
^ Attach a warranty tag to the oil feed pipe after removal.
NOTE:
Refer to Warranty Information section in this TSB for WTC return instructions.
14. Inspect the gasket for damage (removal from the cylinder block not required).
^ Reuse the gasket if NOT damaged.
^ Replace the gasket if damaged.
15. Lower the vehicle.
16. Position the new oil feed pipe to the turbocharger and the engine block.
17. Wipe clean and install the (2) copper sealing washers and finger tighten the banjo bolt to the turbocharger (it will be torqued later).
^ Copper washers must be installed (1) above and (1) below the banjo fitting when the banjo bolt is hand threaded into the turbocharger.
18. Lift the vehicle to a suitable height for under vehicle work.
19. Confirm that the gasket on the cylinder block is not damaged and free from any dirt debris.
^ Reuse the existing gasket if not damaged.
NOTE:
The tab on the gasket must point down (as shown).
20. Install the oil feed pipe lower connection flange over the studs and gasket on the cylinder block.
^ Make sure that the tab on the gasket is pointing down.
^ Install the (2) 10 mm nuts and tighten to 87 lb-in (1.0 kgf.m).
^ Remove any shop towels previously placed under the connection flange to soak up the residual oil.
NOTE:
Use degreaser to clean any residual or spilled oil.
21. Lower the vehicle.
22. Tighten the banjo bolt at the turbocharger to 130 lb-in (1.5 kgf.m).
NOTE:
Use degreaser to clean any residual or spilled oil.
23. Install the upper heat shield.
24. Tighten the (3) 10 mm heat shield bolts to 87 lb-in (1.0 kgf.m).
25. Reinstall the 02 sensor connector bracket and the (1) 10 mm bolt to the cylinder head.
^ Tighten the 02 sensor connector bracket bolt to 87 lb-in (1.0 kgf.m).
26. Position the 02 sensor harness into the spacer clip at the white mark and ensure that the remaining harness does not touch the heat shield (as shown below).
27. Reinstall the engine cover.
28. Start the engine and allow to run for several minutes.
29. Raise the vehicle and inspect the connection point at the block for any oil leaks (as shown on the right).
30. Reinstall the lower splash shields.
31. After the engine has been turned off for a few minutes, check engine oil level.
NOTE:
If the engine oil level on the dipstick is above the L (LOW) level up to F (FULL), then no adjustment is required. (Refer to TSB 10-EM-001 for details.)
32. Verify repair.
WARRANTY INFORMATION