Injected
15+ Year Contributor
- 704
- 16
- Apr 29, 2004
-
Houston,
Texas
I just yanked a G4CS out of a 1989 Sonata a few days ago and thought I'd post a thread with some tips for those who are going to try and do the same.
First of all, the G4CS is located in the engine bay of the 1989-1991 Hyundai Sonata and was the only four-cylinder available in the chassis. There was apparently a six-cylinder option, but I have never come across one. This is what the car you are looking for looks like.
Many junkyard veterans will tell you that you should take certain tools with you to the yard. Here's a list of what I brought and what I should have brought with me to extract the short-block.
1. Socket set 8-22mm. Most where 10-14mm, but a few where 17mm, and if you need to take apart parts of the suspension to remove the transmission, you will need several of the larger socket sizes.
2. Wrenches of the same sizes and a 'universal,' adjustable one.
3. Hammer. A five pound one will do.
4. 'Cheater pipe'. Any piece of pipe that will fit over the end of a wrench will do.
5. Screwdriver. Both Philips and flathead.
6. Pry bar. For prying of course.
7. Liquid Wrench for those stubborn, rusted bolts.
8. Hex socket, size 10mm. This is what you will need to remove the head-bolts.
9. Knife for cutting miscellaneous wires, hoses, etc. A hacksaw would be good to, but it isn't as maneuverable in the engine bay.
10. Creepers are nice, the back seat of a Volvo is better.
11. Two friends, preferably of the sasquatch breed. One will do, but why not make a day of it. Enjoy yourselves.
12. Some sort of way to extract the engine from the bay. Whether you are going to lower it or raise it, straps are great. You can cut the seatbelts out of a car if you forget them. See 11.
13. Remember, it is junkyard etiquette to put the parts you removed from the car in the trunk so that someone can find them if they need to.
Step 1. Locate the car. You may have to go to or call several places. Most don't know exactly what cars they have, some do and won't let you into their lot (they pull it). The 'you-pull-it' places are great and you can walk through it like an art gallery. Once you have located the car, you should be prepared to pull it. I've seen an engine disappear rather quickly, so be prepared to take it if you get the chance.
Step 2. Take off the exhaust system. Most junkyards will have cut off the catalytic converter making the removal of the exhaust system easier than separating the header from the system and removing it with the head. The remaining system will be suspended by a hanger and the bolts in the head. Removing the radiator fan, heat shield and oil dipstick tube bracket helps with the removal of the exhaust system as well.
Step 3. Remove the passenger side engine mount.
Step 4. Remove power steering pump, A/C compressor, alternator and brackets. You can do this after you pull the engine, but stripping the engine down while its still in its bay is easy and makes removal that much easier. Also take off the timing belt cover. Cut the belts including the timing belt to make things go more quickly.
Step 5. Disconnect the intake manifold from the chassis. Leave it attached to the head, but everything attached to it like the fuel rail, wiring harness, intake pipe, etc. should be removed. The throttle body can stay.
Step 6. Remove the head. Take the valve cover off and remove the hex bolts that hold the head to the block. At this point the head/intake manifold should lift right off.
Step 7. Detach the transmission. It may be easier, depending on a few factors, to remove the CV joints, detach the remaining mounts and lower the transmission and engine then separate them. We ran into a little trouble when the torque converter (automatic transmission) wouldnt allow an easy separation from the engine. If this is the case, separating the converter from the engine should allow the engine to be lifted out after disconnecting the transmission mount, remaining engine mounts and pulling them apart.
Step 8. Lift or lower your engine into a cart or wheelbarrow. Its kind of awkward and weighs quite a bit. Remove any remaining things you dont need at this point.
I'll attach a picture of the engine bay.
Hope this helps.
Should I post this in the tech articles section?
First of all, the G4CS is located in the engine bay of the 1989-1991 Hyundai Sonata and was the only four-cylinder available in the chassis. There was apparently a six-cylinder option, but I have never come across one. This is what the car you are looking for looks like.
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Many junkyard veterans will tell you that you should take certain tools with you to the yard. Here's a list of what I brought and what I should have brought with me to extract the short-block.
1. Socket set 8-22mm. Most where 10-14mm, but a few where 17mm, and if you need to take apart parts of the suspension to remove the transmission, you will need several of the larger socket sizes.
2. Wrenches of the same sizes and a 'universal,' adjustable one.
3. Hammer. A five pound one will do.
4. 'Cheater pipe'. Any piece of pipe that will fit over the end of a wrench will do.
5. Screwdriver. Both Philips and flathead.
6. Pry bar. For prying of course.
7. Liquid Wrench for those stubborn, rusted bolts.
8. Hex socket, size 10mm. This is what you will need to remove the head-bolts.
9. Knife for cutting miscellaneous wires, hoses, etc. A hacksaw would be good to, but it isn't as maneuverable in the engine bay.
10. Creepers are nice, the back seat of a Volvo is better.
11. Two friends, preferably of the sasquatch breed. One will do, but why not make a day of it. Enjoy yourselves.
12. Some sort of way to extract the engine from the bay. Whether you are going to lower it or raise it, straps are great. You can cut the seatbelts out of a car if you forget them. See 11.
13. Remember, it is junkyard etiquette to put the parts you removed from the car in the trunk so that someone can find them if they need to.
Step 1. Locate the car. You may have to go to or call several places. Most don't know exactly what cars they have, some do and won't let you into their lot (they pull it). The 'you-pull-it' places are great and you can walk through it like an art gallery. Once you have located the car, you should be prepared to pull it. I've seen an engine disappear rather quickly, so be prepared to take it if you get the chance.
Step 2. Take off the exhaust system. Most junkyards will have cut off the catalytic converter making the removal of the exhaust system easier than separating the header from the system and removing it with the head. The remaining system will be suspended by a hanger and the bolts in the head. Removing the radiator fan, heat shield and oil dipstick tube bracket helps with the removal of the exhaust system as well.
Step 3. Remove the passenger side engine mount.
Step 4. Remove power steering pump, A/C compressor, alternator and brackets. You can do this after you pull the engine, but stripping the engine down while its still in its bay is easy and makes removal that much easier. Also take off the timing belt cover. Cut the belts including the timing belt to make things go more quickly.
Step 5. Disconnect the intake manifold from the chassis. Leave it attached to the head, but everything attached to it like the fuel rail, wiring harness, intake pipe, etc. should be removed. The throttle body can stay.
Step 6. Remove the head. Take the valve cover off and remove the hex bolts that hold the head to the block. At this point the head/intake manifold should lift right off.
Step 7. Detach the transmission. It may be easier, depending on a few factors, to remove the CV joints, detach the remaining mounts and lower the transmission and engine then separate them. We ran into a little trouble when the torque converter (automatic transmission) wouldnt allow an easy separation from the engine. If this is the case, separating the converter from the engine should allow the engine to be lifted out after disconnecting the transmission mount, remaining engine mounts and pulling them apart.
Step 8. Lift or lower your engine into a cart or wheelbarrow. Its kind of awkward and weighs quite a bit. Remove any remaining things you dont need at this point.
I'll attach a picture of the engine bay.
Hope this helps.
Should I post this in the tech articles section?
This is great info on the 4GCS, thanks. Did you only take the crank? What did it cost you at the junkyard?
