Hyundai Sonata 1991 Install guide

HYUnCRI 1991
Shop
Manual
son

TITLE SECTION
General Information 00
Lubrication and Maintenance 10
Engine 20
Cooling System 25
Engine Electrical System 27
Intake & Exhaust System
28
Emission Control System 29
Fuel System 31
Clutch 41
Manual Transaxle 43
Automatic Transaxle 45
Drive Shaft and Front Axle 49
Front Suspension 54
Rear Suspension 55
Steering System 56
·Brake System 58
Body
(Interior and Exterior)
60
Body Electrical System 90
Air Conditioning SyStem 97
Appendix (Electrical wiring system) -
HYUnDRI
SOndTd
Shop Manual
FOREWORD
This shop manual is intended for use by service
technicians of authorized Hyundai dealers
to help
them provide efficient and correct service and
maintenance
on 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 to change without any notice.
As for the modifications affecting service performance,
dealers shall be provided technical service bulletins or
supplementary volumes.
This book may not be reproduced
or copied, as a whole
or as apart. without the wrinen permission of
publisher.
APR. 1990. Printed in Korea
HVUnOr:l1 MOTOR COMPr:lnV
CONTENTS
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HVunDR MOTOR COMPRnY
Seoul Korea
Printing: APR. 28.
1990
Publication No.: YS-900406
Printed
in Korea

GENERAL
INFORMATION-

GENERAL INFORMATION
HOW TO USE THIS MANUAL
GENERAL INFORMATION
YOOCAOA
This manual is divided into 19 sections. This first page of each
section is marked
with ablack tab at the edge of the page. You
can
quickly find the first page of each section without looking
through a full table of contents.
Each section includes the essential removal, installation,
adjustment and maintenance procedures for servicing all body
styles. This
information is current as of time of publication.
An INDEX is provided on the first page of each section to guide
you to the item to be replaced.
TROUBLESHOOTING tabills are included for each system to
help you diagnose the system problem and find the cause. The
repair
for each possible cause is referenced in the remedy
column to quickly lead you to 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 or the value to which the
part or assembly is corrected and adjusted. It is given by a
tolerance.
Service limit
Shows the standard for judging the quality of a part or assembly
on inspection and means the maximum or minimum value within
which the part or assembly must be kept functionally or in
strength. It is a
value established outside the range of standard
value.
NOTE, WARNING AND CAUTION
NOTE
Apoint of
information.
YOOCCOA
WARNING
Information about an activity that could cause damage to the
vehicle.
CAUTION
Information about an activity that could cause injury or damage
to
the driver, occupants or repair personnel.
00-2

GENERAL INFORMATION
VEHICLE IDENTIFICATION
NUMBER LOCATION
YOOCDOA
The vehicle identification number (V.I.N) is on the top of the
instrument panel, on the radiator support panel, and the driver's
door post.
VEHICLE IDENTIFICATION NUMBER
Vehicle identification number consists of 17 digit.
®~®®®G)@®®©@
~TTTTTTTT
1) 2) 3) 4) 5) 6) 7) 8) 9)
YOOCEOA
@@@@@(D
I
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 cc
F : 1997 cc
7) Check digit
8) Product year
L-1990
M-1991
S : 2351 cc
T : 2972 cc V6
N-1992
P-1993
9) 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 is stamped at the right front
side on the top edge of the cylinder block.
ENGINE IDENTIFICATION NUMBER
Engine identification number consists of 10 digits.
YOOCGOA
@®®®®
TTTTT
1) 2) 3) 4) 5)
1) Engine fuel
G : Gasoline
@@@@@G)
I
6)
2) Engine range
4 : In line 4cycle 4 cylinder
3) Engine development order
A-Z:
4) Engine capacity
M 1795 cc
P : 1997 cc
5) Product year
S : 2351 cc
T : 2972 cc V6
6) Engine production sequence number
0ססoo1-999999
00-4

Always be sure to cover fenders, seats, and floor areas before
starting work.
CAUTION
The support rod must be inserted into the hole near the edge
of the hood whenever you inspect the engine compartment
to prevent the hood from falling and possibly injuring you.
Assure that the support rod has been released prior to closing
the hood. Always double check to be sure the hood is firmly
latched before driving away.
The following precautions must be followed when jacking up the
vehicle.
1. Block wheels.
2. Use only specified jacking positions.
3. Support
vehicle with safety stands (rigid jacks)
Refer
to the page 00-9.
4. Start the engine only after making certain the engine
compartment is clear of tools and people.
PROTECTION OF THE VEHICLE
A
WORD ABOUT SAFETY
GENERAL INFORMA,
;O~~
YOOCHOA
YOOCJOA
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT YOOCKOA
Be 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 of trouble prior to removing or disassembling
any components.
1. Inspection of parts
Each part when removed should be carefully inspected for
malfunction, deformation, damage, and other problems.
If
the disassembly procedure is complex, requiring many parts
to be disassembled, all parts should be disassembled in a way
that will not affect their performance or external appearance.
DISASSEMBLY YOOCNOA
2. Arrangement of parts
All disassembled parts should be carefully arranged for
reassembly.
Be
sure to separate or otherwise identify the parts to be
replaced
from those that will be reused.
3. Cleaning parts for reuse
All parts to be reused should be carefully and thoroughly
cleaned by the appropriate method.
00-6
I
~
,
J
-U

GENERAL INFORMATION
PARTS
When replacing parts, use HYUNDAI genuine parts.
REASSEMBLY
YOOCPOA
YOOCOOA
Made In
HYUnCRI
Genuine
Parts
Standard values, such as torques and certain adjustments, must
be strictly observed in the reassembly of all parts.
If removed,
these parts should be replaced with new ones.
1. Oil seals
2. Gaskets
3.
a-rings
4. Lock washers
5. Coller pins (split pins)
6. Plastic
nuts
Q
o
Depending on where they are;
1. Sealant should be applied to gaskets.
2. Oil
should be applied to moving components of parts.
3. Specified oil or grease should be applied at the prescribed
locations (oil seals, etc.) before assembly.
ADJUSTMENTS
VOOCROA
Use gauges and testers to correct adjustments to the standard
values.
00-7

1. Be sure to disconnect the battery cable from the negative
(-) terminal of the battery first.
2. Never
pull on the wiring when removing connectors.
3. Locking
connectors must be heard to click if the connector
is secure.
4. Handle sensors and relays carefully. Be careful not to drop
them' or hi: them against other parts.
ELECTRICAL SYSTEM
GENERAL INFORMATION
YOOCSOA
RUBBER PARTS AND TUBING
Always prevent gasoline or oil from touching
tubing.
YOOCTOA
rubber parts or
PRECAUTIONS FOR ACATALYTIC CONVERTER
YOQCUOA
CAUTION
If large amounts of unburned gasoline flow into the converter,
it may overheat and create a fire hazard.To prevent this,
observe the following precautions and explain them to your
customer.
1. Use only unleaded gasoline.
2.
Avoid prolonged idling.
Avoid running the engine at fast idle speed for more than
10 minutes and at idle speed for more than 20 minutes.
3. Avoid spark jump test.
Spark
jump only when absolutely necessary. Perform this
test as rapidly as possible and, while testing, never race the
engine.
4. Avoid prolonged engine compression measurement. Engine
compression tests must be made as rapidly as possible.
5. Do
not run engine when fuel tank is nearly empty. This may
cause the engine to misfire and create an extra load on the
converter.
6. Avoid coasting with ignition turned off and prolonged
braking.
7. Do not dispose of used catalyst along with parts
contaminated with gasoline or oil.
00-8

GENERAL INFORMATION
VEHICLE LIFT
AND SUPPORT LOCATiONS
YOOCVOA
..
-
..
Jack provided with the vehicle
Rigid jack, single or double post
lift
Garage jack
Hbar
lift
The jack provided with
the vehicle (for reference)
Rigid rack (Safety stand) Garage jack (floor jack)
Free wheel type auto lift
(H bar lift)
Double-post lift
Single-post lift
CAUTION
1) Never use a jack at the lateral rod or rear suspension assembly.
2) In order to prevent scarring the centermember, place a piece of cloth on the jack's contact surface (to
prevent corrosion caused by damage to the coating).
3) Never attempt to position a floor jack on any part of the vehicle underbody. >
4) Do not attempt to raise one entire side of the vehicle by placing a jack midway between the front and
rear
wheels. To do so could result in permanent damage to the body.
00-9

LUBRICATION
AND II
MAINTENANCE
SCHEDULED MAINTENANCE TABLE 2
RECOMMENDED LUBRICANTS AND CAPACiTIES 6
MAINTENANCE SERViCE 7

SCHEDULED MAINTENANCE TABLE
SCHEDULED MAINTENANCE TABLE
RECOMMENDED CUSTOMER MAINTENANCE (FOR U.S.A.)
The following maintenance services must be performed to assure good emission control and performance. Keep
receipts for all vehicle emission services to protect your emission warranty.
Where both mileage and
time are shown, the frequency of service is determined by whichever occurs first.
R : REPLACE
I : INSPECT, AFTER INSPECTION, CLEAN, LUBRICATE, ADJUST, REPAIR OR REPLACE IF NECESSARY
MILES X
1000
7.5 15 22.5 30 37.5 45 52.5 60
NO DESCRIPTION KILOMETER X
1000 12 24 36 48 60 72 84 96
MONTHS 5
10 20
30
40
50
60 70
EMISSION CONTROL ITEMS
1ENGINE OIL AND
FILTER R R R R R R R R
2VALVE CLEARANCE (JET VALVE ONLY) I I I I
3FUEL
FILTER R
4FUEL LINES AND CONNECTIONS I
5VACUUM, CRANKCASE VENTILATION HOSES I
6FUEL HOSE, VAPOR HOSE &FUEL FILLER CAP I
7AIR CLEANER
FILTER R R
8SPARK PLUGS R R
GENERAL ITEMS
1DRIVE BELT (WATER PUMP AND ALTERNATOR) I I
2ENGINE COOLANT R R
3TIMING BELT R
4
MANUAL TRANSAXLE OIL I I
5AUTO TRANSAXLE OIL I R I R
6BRAKE FLUID R R
7BRAKE HOSES, LINES I I I I
8
REAR BRAKE DRUMS/LININGS/PARKING BRAKE I I
9BRAKE PADS, CALIPERS, ROTORS IIII
10 EXHAUST
PIPE CONNECTIONS, MUFFLER &SUSPENSION BOLTS II
11
STEERING GEAR RACK, LINKAGE &BOOTS II
12 WHEEL BEARING GREASE II
13 DRIVESHAFTS &BOOTS IIII
10-2

SCHEDULED MAINTENANCE TABLE
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
The following items must be serviced more frequently on vehicles normally used under severe driving conditions.
Refer to the chart
below for the appropriate maintenance intervals.
I : INSPECT. CORRECT OR REPLACE IF NECESSARY
R: REPLACE
MAINTENANCE ITEM MAINTENANCE MAINTENANCE INTERVALS DRIVING
OPERATION CONDITION
ENGINE OIL AND FILTER
R
Every 3.000 miles (4,800 km)
A. B. C. F. H
or 3months
AIR CLEANER FILTER
RMore frequently C. E
SPARK PLUGS REvery
24,000 miles (40.000 km)
B. H
or 18 months
BRAKE PADS. CALIPERS. ROTORS
IMore frequently C. D. G. H
REAR BRAKE DRUMS/LININGS IMore frequently
C. D. G. H
STEERING GEAR RACK LINKAGE IEvery
7.500 miles (12.000 kml
C. D. E. F
&BOOTS or 6months
DRIVESHAFT &BOOTS IEvery
7.500 miles (12,000 km)
C. E. F
or 6months
SEVERE DRIVING CONDITIONS
A-Repeated short distance driving
B-Extensive idling
C-Driving in dusty conditions
D-Driving in areas using salt or other corrosive materials or in very cold weather
E-Driving in sandy areas
F-More than 50% driving in heavy city traffic during hot weather above 90°F (32°C)
G-Driving in mountainous areas
H-Towing atrailer
10-3

SCHEDULED MAINTENANCE TABLE
SCHEDULED MAINTENANCE TABLE
RECOMMENDED CUSTOMER MAINTENANCE (FOR CANADA)
The following maintenance services must be performed to assure good emission control and performance. Keep
receipts for all vehicle emission services to protect your emission warranty.
Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.
R : REPLACE
I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
IKILOMETER X 1 DOD I 12 I
24 I 36 I 48 I 60 I
72 84
96
NO
DESCRIPTION IMILES X 1
DOD
I 75 15 I22.5 I 30 I37.5 I 45 52.5 60
EMISSION CONTROL ITEMS
1ENGINE OIL
AND FILTER
(or every 6months) R R R R R R R R
2JET VALVE CLEARANCE I I I I
3
FUEL FILTER
R
4
FUEL LINES AND CONNECTIONS I
5VACUUM, CRANKCASE VENTILATION HOSES R
6
FUEL HOSE, VAPOR HOSE & FUEL FILLER CAP R
7AIR CLEANER
FILTER R R
8SPARK PLUGS R R
GENERAL ITEMS
1
DRIVE BELT (FOR WATER PUMP, ALTERNATOR AND PIS)
I I
2ENGINE COOLANT (or every 2years) R R
3TIMING BELT R
4
MANUAL TRANSAXLE OIL II
5AUTO TRANSAXLE FLUID I R I R
6BRAKE HOSES, LINES IIII
7BRAKE FLUID (or every 2years) R R
8
REAR BRAKE DRUMS/LININGS/PARKING BRAKE I I
9BRAKE PADS, CALIPERS, ROTORS II I I
10
EXHAUST PIPE CONNECTIONS, MUFFLER &SUSPENSION BOLTS I I
11
STEERING GEAR RACK, LINKAGE &BOOTS II
12 WHEEL BEARING GREASE IJ
13 DRIVESHAFTS &BOOTS I I IJ
10-4

SCHEDULED MAINTENANCE TABLE
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer
to the chart
below for the appropriate maintenance intervals.
I : INSPECT. CORRECT OR REPLACE IF NECESSARY
R: REPLACE
MAINTENANCE ITEM MAINTENANCE MAINTENANCE INTERVALS DRIVING
OPERATION CONDITION
ENGINE OIL & FILTER
REvery
3.000 miles (4.800 km)
A, B. C. F. H
or 3months
CLEANER FILTER
RMore frequently C. E
SPARK PLUGS REvery
24,000 miles (40,000 kml
B. H
or 18 months
BRAKE PADS. CALIPERS. ROTORS
IMore frequently
C. D. G. H
REAR BRAKE DRUMS/LININGS IMore frequently C. D. G. H
STEERING GEAR RACK LINKAGE IEvery
7,500 miles (12,000 km)
C. D. E. F
&BOOTS or 6months
DRIVESHAFT &BOOTS IEvery
7.500 miles (12,000 km)
C. E. F
or 6months
SEVERE DRIVING CONDITIONS
A-Repeated short distance driving
B-Extensive idling
C-Oriving in dusty conditions
D-Driying in areas using salt or other corrosive materials or in very cold weather
E-Driving in sandy areas
F-More than 50% driving in heavy city traffic during hot weather above 90°F 132°q
G-Driving in mountainous areas
H-Towing atrailer
10-5

RECOMMENDED LUBRICANTS AND CAPACITIES
RECOMMENDED LUBRICANTS AND CAPACITIES
RECOMMENDED LUBRICANTS
Parts Specifications Remarks
Engine oil API classification
SF, SF/CC or SG
For further details, refer to
SAE viscosity number
Manual transaxle Hypoid gear oil, SAE
75W-85W
Automatic transaxle GENUINE HYUNDAI ATF AUTO- MOPAR ATF
PLUS TYPE 7176
MATIC TRANSMISSION FLUID, is recommended lubricant
MOPAR ATF PLUS
TYPE 7176, OR
DIAMOND ATF SP
Brake Brake
fluid DOT 3 or equivalent
Power steering A
TF DEXRON@II
Wheel bearing SAE
J310a Multipurpose grease
NLGI grade #2 or equivalent
Coolant Ethylene glycol base for AI radiator
Transaxle linkage, parking SAE
J310a Multipurpose grease
brake cable mechanism, hood NLGI grade
#2 or equivalent
lock and hook, door latch, seat
adjuster, tailgate latch
Door hinges Engine oil
Pedal bearing, SAE
J310a Chassis grease
strut insulator bearing NLGI grade
#0 or equivalent
LUBRICANTS CAPACITIES
Description
Engine oil
Oil pan
Oil
filter
Total
Cooling system
Manual transaxle
Automatic transaxle
Power steering
10-6
Capacities
3.5 lit (3.698 U.S. qts., 3.081 Imp.qts.)
0.4 lit (0.423 U.S. qts., 0.352 Imp.qts.)
3.9 lit (4.121 U.S. qts., 3.433 Imp.qts.)
7.0 lit (7.4 U.S. qts., 6.2 Imp.qts.)
2.5 lit (2.642 U.S. qts., 2.201 Imp.qts.)
5.8 lit (6.129 U.S. qts., 5.106 Imp.qts.)
0.9 lit (0.951 U.S. qts., 0.792 Imp.qts.)
Remarks

Tightening torque
Drain plug
.... 34-44 Nm (350-450 kg.cm, 25-33 Ib.lt)
1. Warm up the engine.
2. Remove the filler cap (on the rocker cover), and drain the
engine oil
(with the drain plug removed).
3. Tighten the drain plug.
MAINTENANCE SERVICE
CHANGING THE ENGINE OIL
MAINTENANCE SERVICE
Y10EAOA
4. Fill the crankcase with fresh oil through the filler port.
Dry fill
3.90 lit. (4.12 U.S.qts., 3.43 Imp,qts)
Drain and refill
Without oil filter: 2.9 lit (3.06 U.S.qts., 2.55 Imp.qts.)
With oil filter: 3.3 lit (3.49 U.S.qts., 2.90 Imp.qts.)
5. Pull the dipstick out in order to check the oil level.
6. Install the filler plug.
7. Recheck the level of the engine oil alter aroad test.
Recommended engine oil
API SF, SF/CC or SG
SAE 20W-20, 20W-40, 20W-50 (ABOVE 32°F OR O°C)
10W-30, 10W-40, lOW-50 (ABOVE -10°F OR -23°C)
5W-20, 5W-30, 5W-40 (BELOW 60°F OR 16°C)
REPLACEMENT OF THE ENGINE OIL FILTER Y10E8OA
1. Replace the oil filter at the time of every oil change.
2. Use a filter wrench (available commercially) to remove the
oil filter.
3. Drain the oil in the filter.
10-7

MAINTENANCE SERVICE
4. Lightly coat the O-ring (1) of the new oil filter with engine
oil, and install the filter by completely turning it by hand.
Valve Clearance Adjustment
As the intake and exhaust valves are equipped with auto-lash
adjustment mechanisms,
there is no need for valve clearance
adjustment. The proper functioning of the auto-lash mechanism
may be determined by checking
for tappet noise. When there is
tappet noise or any unusual noise, check the auto-lash by
removing it.
VALVE CLEARANCE
(Check and adjust as required)
Y10ECOA
'J::::j~~_AutO-laSh
adjuster
Intake and Exhaust Valves
The auto-lash adjuster is installed to the rocker arm so that the
valve clearance adjustment is maintenance-free.
For additional
information regarding the auto-lash adjuster, refer
to "ENGINE" section.
Jet Valve
CAUTION
1. The cylinder head bolts should be retightened before
attempting this adjustment.
2. If the jet valve clearance is not good, this will affect not
only the exhaust gas level, but also be the cause of engine
trouble. It is, therefore, important that the correct
adjustment procedures be followed, as described here.
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches BOoC to 95°C (176°F to
203°F).
3. Check the ignition timing and idling speed, and adjust if
necessary.
4. Remove
the rocker cover.
5. Remove timing belt front upper cover.
6. Turn crankshaft clockwise and align with camshaft sprocket
timing mark.
10-8
/p/,*
/Timing
mark
Timing mark (on camshaft sprocket)
(on cylinder head) ~ ... _