1.6L GDI DOHC Non-Turbo Engine Assembly for 2020-2022 Hyundai Sonata

A quick look at your own vehicle makes sure the right engine shows up:

• Confirm that the 8th digit of your VIN is '2' to verify the 1.6L Turbocharged engine.
• Locate the engine code stamped on the machined boss on the cylinder block near the bellhousing flange and verify it starts with 'G4FP'.
• Confirm your vehicle is Front-Wheel Drive (FWD) with an 8-speed automatic transmission.
• Verify that your existing turbocharger, wastegate actuator, and exhaust manifold are in good, reusable condition.

What the install really takes — plan and budget with confidence:

Special tools this job needs:

• Engine hoist/crane and load leveler
• OEM-compatible OBD-II diagnostic scanner with bi-directional control (Hyundai GDS/KDS or equivalent)
• Fuel line disconnect tools
• Torque wrench / torque-angle gauge

Budget for these consumables at install:

• Engine Oil (OE-spec 0W-20 or 5W-30 API SP / ILSAC GF-6 / ACEA C5/C6, approx. 4.5 to 5.1 quarts)
• Oil Filter (Genuine Hyundai OEM spin-on oil filter)
• Oil Drain Plug Gasket (New crush washer)
• Coolant (OE-spec ethylene glycol-based phosphate coolant / Hyundai-specific coolant)
• Spark Plugs (New NGK/Denso Iridium spark plugs gapped to spec)
• Intake manifold gasket
• Exhaust manifold gasket
• Valve cover gasket
• Fuel pump O-ring / high-pressure fuel pipe (one-time-use torque-to-yield part)
• Torque-to-yield bolts (cylinder head bolts, harmonic balancer bolt, flywheel/flexplate bolts)

What your vehicle’s computers will need after the swap:

What’s involved: CVVD Position Learning / Calibration and ECM Adaptive Value Reset

A dealer-level scan tool (Hyundai GDS-M / KDS or equivalent high-end bi-directional scanner) is required to perform the CVVD learning procedure. If this is not done, the engine may run in a limp-home mode or trigger DTC P193600 or P193100. Sources differ on whether programming is model-dependent or strictly required; chosen 'yes' as the safer position due to mandatory CVVD learning.

Pro tips for a smooth first start-up — hand them to whoever does the install:

• CVVD Actuator Alignment: The CVVD actuator on the cylinder head is highly sensitive. If the shaft is turned manually or misaligned, it will trigger a P193600 or P193100 code. Follow exact alignment procedures and perform CVVD learning calibration.
• High-Pressure Fuel Pipe: The metal line connecting the high-pressure fuel pump (HPFP) to the fuel rail is a one-time-use component. Reusing this pipe is a major safety hazard prone to micro-fractures and fuel leaks.
• Joint Connector JE102: Pay close attention to the wiring harness joint connector JE102 on the intake manifold. Inspect this connector or perform the TSB 23-EE-005H splice repair before dropping the engine in.
• Torque-to-Yield Bolts: Cylinder head bolts, harmonic balancer bolts, and flywheel/flexplate bolts are torque-to-yield and must be replaced if removed.
• Turbocharger Transfer: Carefully inspect your original turbo for shaft play, oil leaks, or damaged fins before reinstalling it on the replacement engine.

Easy to get right once you know them:

• Reusing the High-Pressure Fuel Pipe: Attempting to reuse the high-pressure fuel line, which results in high-pressure fuel leaks or engine fires.
• Failing to Perform CVVD Learning: Skipping the mandatory CVVD position learning calibration, leading to poor running conditions and error codes.
• Using Non-OEM Oil Filters: Using cheap, aftermarket oil filters that cause dry starts, timing chain rattle, and low oil pressure warnings.
• Not Swapping the Purge Control Valve: Failing to replace the purge control check valve with the redesigned version under active recall (Recall 286 / 25V-803).
• Ignoring Turbo Condition: Moving a worn-out or failing turbo onto the replacement engine, which can contaminate and damage the new engine.
• Improper ECU/Immobilizer Handling: Assuming the engine is plug-and-play without preparing for potential ECU programming or security relearn procedures.
• Incorrect Oil Change Intervals: Extending oil changes beyond the recommended 5,000-mile interval for GDI turbo engines.

Not issues with the units on this page — the manufacturer documented these for every engine of this family, wherever you buy one. Handy for your installer: