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