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1991 Hyundai Sonata CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Hyundai REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1991 Hyundai Sonata AUTOMOBILES
Computer Relearn Procedures -> Hyundai
Vehicle: 1991 Hyundai Sonata GL 2.4 L4 GAS
If the battery has been disconnected or the ECM/PCM replaced, drive vehic...
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BRAKE SERVICE PROCEDURES FOR 1991 Hyundai Sonata AUTOMOBILES
HYUNDAI -> Disc Brakes -> CALIPER SERVICE -> Assembly -> Disassembly -> ELANTRA & SONATA -> EXCEL & SCOUPE -> FRONT -> Installation -> REAR -> Removal
Vehicle: 1991 Hyundai Sonata GL 2.4 L4 GAS
EXCEL & SCOUPE
Removal
- Remove brake pads as described previously.
- Disconnect and cap brake line(s).
- Remove caliper attaching bolts and caliper assembly from steering knuckle.
Disassembly
- Remove sleeve, sleeve boot and pin boots, Fig. .
- Protect fingers with shop towel, then blow piston from caliper bore with compressed air.
- Remove piston boot, then pry piston seal from caliper bore using a suitable screwdriver.
Assembly
- Clean all components with suitable cleaner.
- Inspect caliper bore, piston and carrier for damage or excessive wear.
- Apply rubber grease to new piston seal, then install piston...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Hyundai Sonata AUTOMOBILES
Hyundai -> Fuel Filter Scheduled Maintenance -> 1990-06 Excel & Sonata -> Normal Service -> Severe Service
Vehicle: 1991 Hyundai Sonata 2.4 L4 GAS
Normal Service
Replace every 5...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Hyundai Sonata AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1991 Hyundai Sonata 3.0 V6 GAS
- Raise and support vehicle, then remove front wheel.
- Remove nut from tie rod end.
- Using tie rod end puller tool No. 09568-31000, or equivalent, disconnect tie rod end from knuckle.
- Remove nut from lower control arm ball joint stud.
- Disconnect lower control arm ball joint from knuckle using tie rod end puller tool No. 09568-31000, or equivalent.
- Remove driveshaft nut from hub.
- Using axle shaft puller tool No. 09526-11001, or equivalent, remove driveshaft from hub.
- Insert suitable pry bar...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Hyundai Sonata AUTOMOBILES
Starter, Replace
Vehicle: 1991 Hyundai Sonata GLS 2.4 L4 GAS
- Disconnect battery ground cable at battery.
- Remove terminal nut and wire from B terminal.
- Remove starter mounting bolts.
- Remove starter from vehi...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Hyundai Sonata AUTOMOBILES
Hyundai -> Electronic Brake Force Distribution (EBD)/Parking Brake Warning Lamp ->
Vehicle: 1991 Hyundai Sonata 2.4 L4 GAS
The EBD/Parking Brake warning lamp is used to warn of a system fault. It will be lit during engine start-up, but should go out when the self-diagnostic system determines that the system is functioning properly. The lamp will also illuminate when the parking brake is in the applied position. If the lamp EBD/Pa...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Hyundai Sonata AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 1991 Hyundai Sonata GLS 3.0 V6 GAS
Inlet
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at heater core.
- Remove hose from heater core.
- Reposition hose clamp at connecting pipe.
- Remove hose from connecting pipe.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Disconnect battery ground cable.
- Drain cooling system into a suitable container by loosening drain plug of radiator.
- Reposition hose clamp at...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Hyundai Sonata AUTOMOBILES
Serpentine Drive Belt, Replace -> Alternator and Water Pump -> Power Steering and Air Conditioning
Vehicle: 1991 Hyundai Sonata GLS 2.4 L4 GAS
Alternator and Water Pump
- Disconnect battery ground cable from battery.
- Loosen alternator pivot bolt.
- Loosen tensioner lockbolt.
- Loosen tensioner adjuster bolt.
- Remove alternator and water pump drive belt.
- Clean and inspect belt surfaces of all pulleys.
- Reverse procedure to...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Hyundai Sonata AUTOMOBILES
Component location diagrams for most 1991 Hyundai Sonata cars and light trucks sold in the U.S. from 1990+.
Roof & Trunk Room Lamp Extension Harness Diagram for 1991 Hyundai Sonata 3.0 V6 GAS Components on diagram: |
Control Harness No.1 Diagram for 1991 Hyundai Sonata 3.0 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1991 Hyundai Sonata AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Hyundai Sonata cars and light trucks sold in the U.S.
1991 Hyundai Sonata 2.4 L4 GAS Wiring Diagram Components on diagram: |
1991 Hyundai Sonata GLS 2.4 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Hyundai Sonata AUTOMOBILES
OEM TSB listings for most 1991 Hyundai Sonata cars and light trucks sold in the U.S. from 1985+.
Document: ALARM SELF ACTIVATES - HOOD SWITCH PAD REPLACEMENT Vehicle: 1991 Hyundai Sonata 2.4 L4 GAS |
Document: GUIDELINES AND TORQUE SPECIFICATIONS OF ENGINE FASTENERS USING THE TORQUE-ANGLE METHOD Vehicle: 1991 Hyundai Sonata 2.4 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Hyundai Sonata AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Hyundai Sonata cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Hyundai Sonata cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Hyundai Sonata cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Hyundai Sonata cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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