Hyundai Sonata Engine Swap: Powertrain Installation, First Start & Initial Test Drive

Subframe and Powertrain Reinstallation

• 🛠️ The subframe was carefully lowered into place using a plumb bob for alignment, with the goal of lining up mounting points.
• 💡 The original struts were retained due to differences in sway bar link length and brake hose brackets, avoiding potential fabrication.
• 🔩 Bolts for the subframe and associated brackets were secured, with some difficulty in locating specific bolts, necessitating a trip to the junkyard.

Initial Startup and System Checks

• ⚡ The engine was temporarily hooked up to the throttle body, and the battery was charged for the first start.
• ⚙️ Initial checks included ensuring the car was in neutral or park before attempting to start, and priming the fuel pump.
• ⚠️ The engine started and ran, showing oil pressure, but an exhaust leak was noted, and the engine light remained on, initially attributed to a knock sensor code.

Fluid Fills and Component Installation

• 💧 The engine received almost five quarts of oil, reaching the 'AD' mark, and transmission fluid (Velv SP234) was added.
• 🔧 Strut bolts were tightened, and the AC system was charged, with the compressor appearing functional and blowing cold air.
• 💨 The exhaust flex pipe was identified as the source of a leak, requiring replacement.

Post-Startup Checks and Preparations

• 🚗 The steering column was reconnected, and the shift linkage was adjusted while the transmission was in park.
• 💡 The engine light was checked and found to be related to a misfire code (1326), not the harness swap.
• 💨 The car was taken outside for initial testing; brakes were functional but noisy, and the transmission appeared to shift through gears, including reverse.

Parts Acquisition and Next Steps

• 🛒 A list of needed parts was compiled for a trip to Wilbert's U-Pull-It, including fender liners, plastic underbody components, airbox, and battery hold-down hardware.
• 🔧 Other identified issues include a coolant leak on the transmission side, a broken clock spring (causing airbag and stability control lights, and non-functional horn), and the need for a new flex pipe.
• ✅ The team plans to finish topping off coolant, address the leaks, and complete the remaining repairs and alignment in subsequent videos.