Hyundai Forums banner

How To Replace Oil Control Valve on 2.4L Sonata - with pics

135K views 79 replies 35 participants last post by  Dog Patch Steve  
#1 · (Edited by Moderator)
Disclaimer - This method worked for me. Your vehicle may be different than mine or you could run into other problems I didn’t experience. This post is only for informative purposes. Don’t blame me if you try this and damage something. If you have any comments or questions about what I did, feel free to post them.

Diagnosis
The check engine light has been illuminating intermittently on my 2007 Sonata GLS. The car is also difficult to start sometime, requiring more cranking than usual for the engine to fire. I’ve checked it multiple times and the only code is P0011 for “timing over-advanced or system performance (Bank 1).” Researching this, I found the likely culprit was the Oil Control Valve (OCV). I decided to replace it on my car. I bought the part today and installed it.

The factory service manual has additional diagnostic procedures to determine if the OCV is bad.

What You’ll Need
I used the following tools:
3/8" drive ratchet
19mm deep socket
Extension
Pliers
Torx T30 bit
Torque wrench for properly tightening bolts. This is optional, but I highly recommend properly torquing all bolts.
Image




You’ll also need a new OCV. The MSRP is $53. My local dealer had one in stock. The part number is 243552G000.
Image




This is a revised part. It is slightly different than the original. the new OCV is on top.
Image




Location and removal
Here is where you’ll find the OCV. NOTE - I have removed my engine cover, as I feel it serves no purpose. If your car still has the cover, you may need to remove it.
Image




This is what the general area looks like. The first step is removing a hose that's in the way. Loosen the two clamps holding it in place. I’ve marked the clamps with the red arrows. I used a pair of pliers to loosen them.
Image

Image




Then, remove the terminals connecting the wires to the sensors. The top terminal has a small button that you push down while pulling the connector off. You can’t see it in this pic, but there is a small wire clip on the lower connector that you need to pry off with a slotted screwdriver.
Image




The OCV is held in place with one T30 torx bolt. On my vehicle, the oil temperature sensor was blocking me from accessing the bolt. I had to remove the oil temp sensor, which required using a deep 19mm socket and the extension. Next is removing the OCV bolt. The easiest way to get at the bolt is with a 6” or longer extension.
Image




The bolt turned out to be difficult to remove on my Sonata. It wouldn’t budge and I could feel that it was starting to strip. Stripping out the bolt would be very, very bad, as its location would make it very difficult to drill out. I sprayed it with penetrating oil, which didn’t seem to help very much. I then gave the bolt a few taps with a hammer to loosen up any corrosion holding it in place. I seated the bit in the bolt and gave the extension a few strong taps with a hammer. That seemed to do the trick and the bolt came out. You can then pull out the old OCV.
Image




The bolt was obviously damaged. I wanted to replace it. It is a M6 x 1.0 metric bolt. My local hardware story didn’t have any Torx bolts, so I replaced it with a flanged hex bolt. In the second pic you can see the corrosion on the threads of the old bolt.
Image

Image




Reassembly
Torque Specs (taken from my factory service manual):
Oil Control Valve bolt 7.23 - 8.67 ft. lbs
Oil temperatur sensor 14.46 - 17.35 ft. lbs


Reassembly is the reverse of removal. Install the new OCV and torque the bolt. I used a little anti-seize, so removing the bolt would be easier in the future. Replace the oil temperature sensor and reconnect all wires. Then reinstall the hose. Double check everything, start the car and check for any oil leaks around the oil temperature sensor. You’re done.
 

Attachments

#39 ·
19MM for the Oil Temperature Sensor?

I bought a new OCV and I tried using a 19mm deep socket to remove the OTS which is on the way but the 19mm socket didn't seem to fit the OTS on my 2007 Sonata 2.4L. I cannot get to the oil control valve without removing the oil temp sensor. I tried looking for a 20mm deep socket at home depot but could not find one. Are these common? I found a deep 7/8 SAE but this one was a little bit larger. I think I'll have to buy a whole set of sockets on the range and keep trying until one fits it. Is this clearly it or am I missing something? :confused:
 
#41 ·
I bought a new OCV and I tried using a 19mm deep socket to remove the OTS which is on the way but the 19mm socket didn't seem to fit the OTS on my 2007 Sonata 2.4L. I cannot get to the oil control valve without removing the oil temp sensor. I tried looking for a 20mm deep socket at home depot but could not find one. Are these common? I found a deep 7/8 SAE but this one was a little bit larger. I think I'll have to buy a whole set of sockets on the range and keep trying until one fits it. Is this clearly it or am I missing something? :confused:
You shouldn't have top remove the sensor. If you have it, try just using an extension on your socket wrench to reach the Torx bolt for the OCV. I found I was able to do this when I did my repair a couple years ago.

I did have to disconnect the harness to the OTS; be careful not to lose the retention clip like I did. Nobody carried a replacement, and I had to MacGuyer one using a twist-tie.

If in fact you do have to remove the sensor, then yes you should be able to buy that socket by itself without buying the whole set. If Home Depot doesn't have it, try Lowe's, Sears, "Advance AutoZone", etc.

Good Luck!
 
#40 ·
19mm I think, but the 6 flats need to be real deep inside the socket to allow socket to pass over the electrical connector to grab the sensor' hex
 
#42 ·
Thanks and another OCV removal issue

Thanks, sbr711 and peacefrog_0521! I tried from several different positions but could not get to the OCV torx bolt without removing the OTS sensor. I found out there was a Harbor Freight nearby and I was able to find a deeper 19mm socket.
I then came back home and was able to finally remove the OTS and after that I removed the torx bolt for the OCV. But then, another issue came by. This one seems nasty...

Only the front part of the OCV came out at first and then I was able to remove the middle part of it as well. I cannot remove the circular-grayed part which is on the back. It seems to be stuck in the OCV hole. Any ideas in how to take that piece off? I'm attaching some pictures for additional clarification on my issue. :mad:
 

Attachments

#43 ·
Had that happen with 2.0 in XD Elantra,, took a tap and try to thread some to get bolt into the sleeve and pull out,, but get some brake fluid and dribble around hole and use snap ring plier to expand in the hole and rotate while gently pulling out/in to desolve oil crud to allow sleeve to come out.

After sleeve come out, put pan under engine to catch oil run out, as you'll want to disable ignition so you can crank engine and let oil flow wash out the debris for maybe 10-20 second..

Image
 

Attachments

#46 ·
SBR711, I was able to take off that stripped head bold by manually using a screw extractor and I'm back to the OCV's tail being stuck in the motor. From your response it looks like you threaded the OCV's tail in order to get a bolt in there and try to take that out but by looking at your picture, it seems to me you added a lot of grease and took it out with the tap itself. Could you please explain better how you took yours off? Mine seems to be so stuck that I can't even move it a little...

Thanks a lot!!
Ricardo
 
#49 ·
I personally could not put a drill in there. Very tight space.
What I did was getting a socket that fitted my tap and used a ratched w/ extension. The tap got into the hole almost perfectly and I was able to turn my stuck OCL a little bit but still I think that wasn't enough so I could remove it. I'm getting my car back from the mechanic today and I'll keep trying to remove mine.
 
#50 ·
2.4 liter engine problems

I have an 06 Sonata with a 2.4 liter engine. It had the typical signs of a bad OCV (from the engine codes), so I replaced the OVC with a new one. The new one was shorter than the original one, but some of these threads said that was normal. It ran a little better for a short while, then the engine light came back on and a little while later a ticking noise in the engine was audible. The noise got steadily worse for about 50 miles (we were on a trip) and finally ended with a loud racket and the engine running horribly. I quickly shut off the engine- I am assuming it threw a rod from all indications- haven't had time to investigate thoroughly. Any way that a bad OCV could cause that? BTW, I guess I'm looking for a new 2.4 liter engine now and would welcome any suggestions!
 
#54 · (Edited)
I have a 2007 2.4 Sonata with 125,00 kms. for the last 6 months it has been showing - off and on an engine light, said to be "P11" , caused by a sludged up engine. My Hawkesbury, Ontario Hyundai dealer was trying to convince me that I needed a part for the CCVT that costs $430.00 and would take 6 hours of work to install. Theytold me the timing chains would have to come off to get at the offending part, that was clogged with sludge. Is there any way this could be true? - or am I right in thinking he is a scam artist? The solution given here would help me avoid his estimate of $1200.00 and I could enjoy a happier Christmas! Furthermore what would you do in this case? Would it do any good to report this to Hyundai
 
#55 · (Edited)
My simple P0011 fix

After receiving an estimate for fixing the P0011 code for C$1200, I decided to put my thinking cap on. There are three components involved. (1) the oil filter that sits in the engine block (2) The Oil flow Control Valve or OCV (3) The camshaft actuator sprocket that varies the exhaust valve. I think it is fair to say that the customer is facing a dealer/mechanic mind set - they want to make money for Hyundai. My Hyundai Front desk man wanted badly to replace the most expensive part and remove the camshaft chain-drive (3). The mechanic wanted to replace the most difficult to get at part (oil filter) That means removing the cylinder head. I wanted to replace the easiest part. (OCV). It turns out we were all wrong. Nothing needed replacing. I suggest removing the OCV and inserting a tight fitting polythene tube into the OCV port. Feed the tube to an oil container and start the motor and flush a quart of oil through the filter to unclog it. You can discard the the oil if necessary. Replace the OCV and take the car through 3 heating cycles - allowing the motor to cool down fully each time. The OBDII light will disappear if this tiny filter was the problem. In my case the engine check light disappeared and my vehicle passed the Ontario, Canada Pure Air Test without a problem. My belief is that the filter clogs up because of the weak flow of oil. I also believe this procedure should be an official Hyundai maintenance operation. It is not in the interest of Hyundai to have their cars flunk emissions tests as mine would have. It does not profit Hyundai to have their dealers issue such inappropriate and expensive estimates when all that is needed is a little thoughtful maintenance. It may well be that on occasion expensive procedure and parts are necessary to fix code P0011 but one should first try the simplest and cheapest approach.
 
#56 ·
I've found a rare bird: a mechanic that is both honest and competent. He first advised changing the oil and wait a week or two. Check Engine relit a few days later, so back to the shop to replace the OCV. He showed me the old part; the filter screen had pushed inside the body of the OCV due to dirty oil (my bad.) New OCV and plugs and when the sensor sends a signal, now the camshaft responds. Runs MUCH better.

A month later, new tires/struts and now it rides MUCH better. :grin2:
 
#57 ·
Bumping an old thread.

I'm preparing to replace OCV on 2006 2.4L Sonata. I've been driving with P0011 for a year now.

I'm scared sh**less that OCV will break inside the hole while I try to pull it out. See rcarrega's ordeal upthread.

I'm looking for tips on how to remove OCV safely. Should I try to pull it straight out? Turn it clockwise or counterclockwise?

Any other tips?

Thank you.
 
#59 ·
Okay, I guess I should count myself lucky. Everything came out fairly easily. Both the torx bolt and the OCV. And yes, I had to remove the oil temperature sensor to get to the torx bolt.

Torx bolt:

I followed all the tips shared in this thread:

1. went for a 20 minutes drive to heat the engine
2. soaked the bolt with penetrating oil (PB Blaster)
3. waited 3 hours for the engine to cool off
4. gave the bolt a few good taps with a hammer

The bolt turned without any effort. The thread didn't show any signs of rust. I was surprised to see that. The car is 9+ years old.

OCV:

I was afraid to apply *any* force to the OCV. I wiggled it left and right 20-30 times and then it kinda popped off by itself. There is really no room there to turn the OCV. You can only wiggle it a little bit.


Stephen9666: thank you so much for this thread and the video on youtube. Very nicely done! http://www.hyundai-forums.com/members/stephen9666.html
 
#60 ·
243552-G500 is the new #?

Thanks for the tips, guys. And the excellent writeup by Stephen9666. I have seen conflicting info regarding which is the new redesigned part number.

Is 243552-G500 definitely the new replacement part, and 243552-G000 is the old original part? Hyundai appears to sell both part numbers for the same price, but maybe the just substitute one for the other.
 
#61 ·
I want to say -2G500 is current part,, it is shorter than the old part, and slight smaller body than original removed from cylinder head..

Hyundai dont have sense to pull old parts and toss in scrap..
 
  • Like
Reactions: Karaoke Kop
#63 ·
I have a Sonata 2.4 L 2007 with 84 k miles. Been struggling with P0011 for two months on and off , now very consistent , code comes within 20 miles of driving , every day

The pictures and YouTube were very helpful , thanks!

I successfully changed the OCV ( new design part , about $43 total from Ebay) two days ago ,and everything was good for a whole day , but this morning , after only 5 miles of driving , when starting out from a light , check engine ( P0011) is back again.

Any thoughts of what I can do?

I need to change oil and the filter which are about 4 months old now, topped off recently
 
#66 ·
Warranty....

Dont know to what speed Canada is up to, but was recall in USA when chassis first come out,, we have SST to seat rubber plug to depth in nose of CVVT unit....

Down road here the rubber plug is popping out, we reset, and they pop out again.. when the plug pop out, it fills cover with oil, and oil can squirt out the vent hole of plug at cover..

Hyundai has a new part number on the rubber plug,, it is also black in color.. need to remover CVVT cover that has the electric plug, clean the inside and brush box of motor oil,, clean front of CVVT unit, start rubber plug in hole, assemble cover to the front of engine,, use SST and seat plug to correct depth..

When done, use GDS to clear codes,, go to SOFTWARE MANAGEMENT,, reset engine adaptive,, and do the E-CVVT thing,, couple spaces down the menu in Software Management screen..

Start engine,, it'll take a little longer crank time to fire up, that normal after reset.. fine from there on out