Sonata Dohc swap walkthrough

[reiketsutsukigami]

this is at the request of 4g64 turbo i dont have many pics so ill add them as i find pics that work but its pretty straightforward even without them.
first off if your using a j/y head id get it tested at a local shop for cracks and levelness of the surface dont want to start off with a problem.
secondly i have a parts list for midnightbear already on the site. your gonna wanna make sure you have all of the parts before you start this as it gets really time consuming otherwise. but if you have all the part this swap should be a few hours at most.
now into disassembly id start by taking the passenger side wheel off, the behind the wheel there should be a cover as part of the wheel well held on by 2 12mm bolts up in the lip if your laying down youll see them in there.
once you have that off start removing your timing covers there should be 4-5 10mm bolts on the lower cover and i think 3-4 on the top cover, then remove the t belt tensioner held on by 2 12mm bolts and then remove the t-belt.
with the belt off you can now start on the head unbolt the exhaust manifold i cant remember the sizes of these i think 5 12mm and 2 14mm but i cant recall once thats off slide the manifold off the studs and you can let it hang there.
now this step is up to you. you can completely remove the i/m and take it off first or leave it on and pull the head with it still attatched like i did i think its easier so ill walkthrough keeping it on.
if you reach underneath the i/m you should feel a big bracket bolting it to the block unbolt the bracket from th i/m should be 2 14mm bolts.
next remove your cai airbox whatever you have and remove the throttle body 4 12mm bolts you can keep the throttle cable attached but you have to remove the tps wire clip just unclip it.
before your start this part if you havent already done so drain your fluids coolant and oil. now back to the throttle body remove the coolant lines from the head you can leave them attached to the t/b unplug the iac plug or if you can get it far enough out without unplugging it do it.
now your going to remove all the vacuum lines id suggest labeling or remembering where they all went this includes the brake booster line and pull the entire map sensor off the i/m 2 8or 10mm bolts.
unbolt all the emission control solenoids from the i/m check for anything else i forgot and remove it.
now to the head itself unbolt the valve cover a couple 10mm bolts once you have that off there are 10 12point 12mm bolts in the bottom of the head unbolt them you may need a breaker bar once there off start pulling the head you should be able to pull it right off.

[reiketsutsukigami]

now for prep assuming you already have the other head cleaned checked your going to remove all the gasket material from the surface of your block.
while you have the head off remove the i/m bracket from the block and bolt the sonata one on.
put the new gasket on. take the sonata head check the o-rings on the crossover tube and if theyre not smoked coat them lightly with grease and put one end into the head or the block your choice now lower the head onto the block and make sure the crossover tube goes in right as you lower it on.

[Isaurio]

Nice bro. Do you have any CEL with the setup and evo ECU

[reiketsutsukigami]

now id recommend new head bolts or do what i did and just go to studs while you have the head off. but bolt the head down to torque specs and start the re assembly bolt on the exhaust mani bolt the t/b to the sonata i/m bolt the i/m to the bracket on the block. squeeze the map sensor into the sonata i/m kinda difficult fit but it works.
hookup all the vacuum lines find new places to mount the emmission solenoids you will probably have to extend a lot of wires its not a problem just do it. take your 8g coil packs and put the sonata wires and boots onto them and bolt them in. now onto timing again if you have the 94gs belt just time it right and put the belt tensioner back on put you lower t-cover back on if your using evo cam gears space out the the upper cover so it fits i havent done this so i dont know the exact spacing or what to use ive been running with no upper cover for over a year double check everything make sure nothings left out or forgotten im gonna double check this whole tut later to make sure i didnt forget anything anyone sees anything i missed please let me know any questions just ask.

[reiketsutsukigami]

i still have cam and crank pos sensor codes even after swapping to evo sensors and evo cams but i think its more a wiring issue than anything.

[underated]

how come you dont use the evo intake manifold and TB?

[reiketsutsukigami]

this is assuming you don't have either of those but those make this much better and easier.

[underated]

oh ic i would highly recommend to anyone doin ght swap to get an evo intake manifold... it saves room, looks nicer, and allows you to use a strut bar (found that out the hard way)

[duh2150]

take your 8g coil packs and put the sonata wires and boots onto them and bolt them in.

only the boots fit the coil and sonata wires dont fit only evo 8

also i agree with underated, about the evo 8 Intake manifold, my oem eclipse bar needed washers and the evo 8 IM has taps for the BOV if your going turbo with it, i might switch just for that reason

[reiketsutsukigami]

i forgot that i modded the wires to fit XD sorry wasnt too hard but ehh not worth the hassle just get the evo stuff.

[underated]

only the boots fit the coil and sonata wires dont fit only evo 8

also i agree with underated, about the evo 8 Intake manifold, my oem eclipse bar needed washers and the evo 8 IM has taps for the BOV if your going turbo with it, i might switch just for that reason

Aaron there are a couple on evom right now for under 100 if your interested.

[duh2150]

ill be searching for sure

[djhah]

I thought the evo im wouldn't bolt up to the sonata head?

[underated]

it does thats what im using right now

if anyone is interested 2 IM's 100 shipped each and 2 TB's 100 shipped each
http://forums.evolutionm.net/sale-en...o-8-turbo.html