Hyundai Sonata 1991 Install guide

HYUnCRI 1991

Shop

Manual

son

TITLE SECTION

General

Information

Lubrication

and

Maintenance

Engine

Cooling

System

Engine Electrical

System

Intake

Exhaust

System

Emission

Control

System

Fuel

System

Clutch

Manual

Transaxle

Automatic

Transaxle

Drive

Shaft

and

Front

Axle

Front

Suspension

Rear Suspension 55

Steering

System

·Brake

System

Body

(Interior

and Exterior)

Body

Electrical

System

Air

Conditioning

SyStem

Appendix

(Electrical

wiring

system)

HYUnDRI

SOndTd

Shop Manual

FOREWORD

This shop manual is intended for use by service

technicians of authorized Hyundai dealers

help

them provide efficient and correct service and

maintenance

Hyundai vehicle.

All the contents of

this

manual. including

drawings

and

specifications, are

the

latest available at

the

time

of publication. However. specifications and procedures

are

subject

change

without

any notice.

for

the

modifications affecting service performance,

dealers shall

provided technical service bulletins or

supplementary volumes.

This book may not be reproduced

copied, as a

whole

apart.

without

the

wrinen

permission of

publisher.

APR.

1990.

Printed in Korea

HVUnOr:l1

MOTOR

COMPr:lnV

CONTENTS

•

HVunDR

MOTOR

COMPRnY

Seoul Korea

Printing: APR. 28.

1990

Publication No.: YS-900406

Printed

Korea

GENERAL

INFORMATION-

GENERAL

INFORMATION

HOW TO USE THIS

MANUAL

GENERAL INFORMATION

YOOCAOA

This

manual

is divided

into

sections.

This

first

page

each

section is marked

with

ablack tab at

the

edge

the

page. You

can

quickly

find

the

first

page

each section

without

looking

through

full

table

contents.

Each section

includes

the

essential

removal,

installation,

adjustment

and

maintenance

procedures

for

servicing all body

styles. This

information

current

time

publication.

INDEX

is provided on

the

first

page

each section to

guide

you to

the

item

be replaced.

TROUBLESHOOTING

tabills

are

included

for

each system

help you diagnose

the

system

problem

and

find

the

cause. The

repair

for

each possible cause is

referenced

the

remedy

column

quickly

lead you

the

solution.

DEFINITION OF

TERMS

Standard Value (Service standard)

YOOCBOA

Indicates

the

value

used as

the

standard

for

judging

the

quality

of apart or assembly on

inspection

the

value

which

the

part

assembly is corrected and adjusted. It is given by a

tolerance.

Service

limit

Shows

the

standard

for

judging

the

quality

of a

part

assembly

inspection and means the maximum

minimum value within

which

the

part

assembly

must

be kept

functionally

strength. It is a

value

established

outside

the

range

standard

value.

NOTE,

WARNING

AND

CAUTION

NOTE

Apoint of

information.

YOOCCOA

WARNING

Information

about

activity

that

could

cause

damage

the

vehicle.

CAUTION

Information

about an

activity

that

could cause

injury

damage

the

driver, occupants

repair personnel.

00-2

GENERAL INFORMATION

VEHICLE IDENTIFICATION

NUMBER

LOCATION

YOOCDOA

The vehicle identification

number

(V.I.N) is on

the

top

the

instrument

panel, on

the

radiator support panel, and the driver's

door post.

VEHICLE IDENTIFICATION

NUMBER

Vehicle identification

number

consists

digit.

®~®®®G)@®®©@

~TTTTTTTT

1) 2)

5) 6) 7)

YOOCEOA

@@@@@(D

10)

1) W.I.C. (World

manufacturer's

identifier)

KMH :Hyundai

Motor

Company's Passenger car

2HM

:Bromont Assembly Plant, Canada

2) Line and drive type

B : Sonata LHD drive vehicle

A : Sonata

RHO

drive vehicle

3) Body type

F : 4Door sedan

4) Series (Body style and version)

1 : Standard 2 : Deluxe (GL) 3Supper deluxe (GLS)

5) Restraint system (Front seat)

o : None seat belt 2Passive system

1 : Active system

6) Engine type

o :

1795

F :

1997

Check

digit

Product year

L-1990

M-1991

S : 2351

T :

2972

N-1992

P-1993

Plant code

UUlsan plant

B : Bromont plant

10) Vehicle production sequence

number

000001-999999

00-3

GENERAL INFORMATION

ENGINE IDENTIFICATION

NUMBER

LOCATION

VOOCfOA

The

engine

identification

number

stamped

the

right

front

side

the

top

edge

the

cylinder

block.

ENGINE IDENTIFICATION

NUMBER

Engine

identification

number

consists

digits.

YOOCGOA

@®®®®

TTTTT

1) 2) 3)

Engine

fuel

G :

Gasoline

@@@@@G)

Engine

range

4 : In

line

4cycle 4

cylinder

Engine

development

order

A-Z:

Engine

capacity

1795

P :

1997

Product

year

S : 2351

T :

2972

Engine

production

sequence

number

0ססoo1-999999

00-4

Always

sure

cover fenders, seats, and

floor

areas before

starting work.

CAUTION

The

support

rod

must

inserted

into

the

hole

near

the

edge

the

hood

whenever

you

inspect

the

engine

compartment

prevent

the

hood

from

falling

and

possibly

injuring

you.

Assure

that

the

support

rod

has

been

released

prior

closing

the

hood.

Always

double

check

sure

the

hood

firmly

latched

before

driving

away.

The

following

precautions

must

followed

when

jacking

the

vehicle.

Block

wheels.

2. Use

only

specified

jacking

positions.

3. Support

vehicle

with

safety

stands (rigid jacks)

Refer

the

page

00-9.

Start

the

engine

only

after

making

certain

the

engine

compartment

clear

tools

and people.

PROTECTION OF THE VEHICLE

WORD

ABOUT SAFETY

GENERAL INFORMA,

;O~~

YOOCHOA

YOOCJOA

PREPARATION OF TOOLS

AND

MEASURING

EQUIPMENT

YOOCKOA

sure

that

all necessary

tools

and

measuring

equipment

are

available before

starting

work

activity

SPECIAL TOOLS

Use special

tools

when

they

are required.

YOOCLOA

00-5

REMOVAL OF PARTS

GENERAL

INFORMATION

YOOCMOA

First

find

the

cause

trouble

prior

removing

disassembling

any components.

Inspection

parts

Each

part

when

removed

should

carefully

inspected

for

malfunction,

deformation,

damage,

and

other

problems.

the

disassembly

procedure

complex,

requiring

many

parts

be disassembled, all

parts

should

disassembled

in a

way

that

will

not

affect

their

performance

external

appearance.

DISASSEMBLY

YOOCNOA

Arrangement

parts

All

disassembled

parts

should

carefully

arranged

for

reassembly.

sure

separate

otherwise

identify

the

parts

replaced

from

those

that

will

be reused.

Cleaning

parts

for

reuse

All

parts

be reused

should

carefully

and

thoroughly

cleaned

the

appropriate

method.

00-6

-U

GENERAL

INFORMATION

PARTS

When

replacing parts, use HYUNDAI

genuine

parts.

REASSEMBLY

YOOCPOA

YOOCOOA

Made

HYUnCRI

Genuine

Parts

Standard values,

such

torques

and

certain

adjustments,

must

strictly

observed

the

reassembly

all parts.

If removed,

these

parts

should

be replaced

with

new

ones.

Oil seals

2. Gaskets

a-rings

4. Lock

washers

Coller

pins

(split

pins)

6. Plastic

nuts

Depending on

where

they

are;

Sealant

should

be applied

gaskets.

2. Oil

should

be applied

moving

components

of parts.

Specified oil

grease

should

be applied

the

prescribed

locations (oil seals, etc.) before assembly.

ADJUSTMENTS

VOOCROA

Use gauges and

testers

correct

adjustments

the

standard

values.

00-7

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