General Repair Procedures

High Voltage Shutoff Procedure

WARNING:
Shut off the high voltage circuit before doing any work related with the high voltage system (Battery Pack Assembly, Power Relay Assembly, HPCU, BMS ECU, Hybrid Drive Motor, Inverter, HSG, LDC Power Cable, Electric Compressor, and so on).

1. Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) cable.
2. Remove the safety plug.
(1) Open the safety plug service cover (A).




(2) Pull out/down the lever (A) in the direction of the arrow after lifting the locking hook (B), and then pull the safety plug.








3. Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
4. Make sure that the capacitor has been discharged.
(1) Remove the rear seat and partition tray trim .
(2) Remove the high voltage front cover (A).





High voltage front cover installation bolt :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)

(3) Measure the voltage between the inverter positive and negative power cable terminals.

Below 30V :High voltage circuit properly shut
More than 30V :High voltage circuit faulty





WARNING:
If the measured voltage is more than 30V, check the removal of the safety plug again.
If it is above 30V even though the safety plug is properly removed, there must be any serious problem in high voltage circuit. In this case, do the DTC troubleshooting first ; don't do any work related to the high voltage system.

Compression Pressure Inspection

NOTE:
If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

CAUTION:
Engine may start anytime the vehicle is in READY mode.1. Warm up and stop engine.

1. Warm up and stop engine.
Allow the engine to warm up to normal operating temperature.
2. Remove the engine cover.
3. Disconnect the injector connectors (A).




4. Disconnect the ignition coil connectors (A).




5. Remove ignition coils (A).




6. Remove spark plugs.
Using a 16mm plug wrench, remove the 4 spark plugs.
7. Check cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole. If possible, place the gauge where it can be seen from inside the vehicle.




(2) Attach the GDS
A. Connect the cable of GDS to the data link connector.
B. Select the vehicle model and then the HCU system.
C. Select the "Engine On Test". See the screens below.
(3) While cranking the engine, measure the compression pressure.
A. With the Brake pedal depressed, press the Start/Stop Button (SSB) one time.
B. If the engine cranks, let it crank about 8 to 10 cycles (until the gauge readings stabilizes) then press the SSB one time to stop the engine from cranking.
C. If the engine does not crank on its own when the SSB is pressed, the GDS should be used to crank the engine. While in the "Engine On Test" follow the instruction on the screen.
D. The "Engine On Test" will start the engine cranking. After the compression readings stabilize (8-10 cycles), press the SSB one time to stop the cranking.
















(4) Repeat steps (1) through (3) for each cylinder.

WARNING:
Be sure ignition is in the OFF mode between each cylinder test.
This measurement must be done while the engine is still near operating temperature.

Compression pressure :
1,283kPa (13.0kgf/cm2, 185psi) / 200 - 250rpm
Minimum pressure :
1,135kPa (11.5kgf/cm2, 164psi)
Difference between each cylinder :
100kPa (1.0kgf/cm2, 15psi) or less

(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (1) through (3) for cylinders with low compression.
A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
8. Reinstall spark plugs.
9. Install ignition coils.

Tightening torque:
3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)

10. Connect the injector connectors and ignition coil connectors.
11. Some DTC's may exist after the inspection test and may need to be manually cleared with GDS.

Valve Clearance Inspection And Adjustment

NOTE:
Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C (68°F)) and cylinder head is installed on the cylinder block.

1. Remove the cylinder head cover.
2. Set No.1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.




(2) Check that the TDC marks (A) of the CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration.
If not, turn the crankshaft one revolution (360°)




3. Inspect the valve clearance.
(1) Check only the valve indicated as shown. Measure the valve clearance.




A. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
B. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting tappet.

Valve clearance
Specification
Engine coolant temperature : 20°C [68°F]
Limit
Intake : 0.10 - 0.30mm (0.0039 - 0.0118in.)
Exhaust : 0.20 - 0.40mm (0.0079 - 0.0157in.)

(2) Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the timing chain cover.
(3) Check only valves indicated as shown. Measure the valve clearance.




4. Adjust the intake and exhaust valve clearance.
(1) Set the No.1 cylinder to the TDC/compression.
(2) Mark the timing chains (A) on the timing marks of the CVVT sprockets.




(3) Turn the crankshaft pulley 15° clockwise.
(4) Remove the service hole bolt(A) of the timing chain cover.





CAUTION:
The bolt must not be reused once it has been assembled.

(5) Insert the SST (09240-2G000) in the service hole of the timing chain cover and release the ratchet.








A. Compress the center rod (A) by pulling out the end plate (B).




B. Insert a ratchet holder through the service hole by turning the holder body (A) clockwise until the end of the center rod touches the tensioner ratchet.




C. Turn the holder body (A) one full turn counterclockwise.




D. Turn the end plate (A) of the center rod (less than one turn) clockwise or counterclockwise until the end plate goes into the groove (B) of holder body.





NOTE:
When turning the end plate, hold the body not to rotate with the end plate.

E. Turn the holder body (A) (less than one turn) counterclockwise until the rotation stops.
F. Tighten the lock nut (B).




(6) Remove the front camshaft bearing cap.
(7) Remove the exhaust camshaft bearing cap and exhaust camshaft.
(8) Remove the intake camshaft bearing cap and intake camshaft.

CAUTION:
When disconnecting the timing chain from the CVVT sprocket, tie or hold the timing chain so it does not fall into the timing cover.

(9) Tie down timing chain so that it doesn't move.

CAUTION:
Be careful not to drop anything inside timing chain cover.

(10) Measure the thickness of the removed tappet using a micrometer.




(11) Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.

Valve clearance [Engine coolant temperature : 20°C(68°F)]
T : Thickness of removed tappet
A : Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A - 0.20mm (0.0079in.)]
Exhaust : N = T + [A - 0.30mm (0.0118in.)]

(12) Select a new tappet with a thickness as close as possible to the calculated value.

NOTE:
Shims are available in 47 size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.690mm (0.1452in.)

(13) Place the new tappet on the valve stem/spring.
(14) Hold the timing chain, and install the intake camshaft and CVVT assembly.
(15) Align the timing marks (A) on the timing chains and CVVT sprockets.




(16) Install the exhaust camshaft and CVVT assembly.
(17) Install the front bearing cap.
(18) Install the service hole bolt after removing the SST from the service hole.

Tightening torque :
11.8 - 14.7N.m (1.2 - 1.5kgf.m, 8.7 - 10.8lb-ft)

NOTE:
To remove ratchet holder, loosen the lock nut and pull out the center rod.

(19) Turn the crankshaft two turns in the operating direction(clockwise), and then check that the TDC marks (A) of the CVVT sprockets are in straight line on the cylinder head surface.




(20) Recheck the valve clearance.

Valve clearance [Engine coolant temperature : 20°C(68°F)]
[Specification]
Intake : 0.17 - 0.23mm (0.0067 - 0.0090in.)
Exhaust : 0.27 - 0.33mm (0.0106 - 0.0129in.)