Hyundai Sonata L4-1997

1998 Hyundai Sonata L4-2.0L Copyright © 2011, ALLDATA 10.
40 Page 1
Hyundai Sonata L4-2.0L 1
Vehicle: Application and ID
Vehicle Identification Number
VEHICLE IDENTIFICATION NUMBER LOCATION

The vehicle identification number (V.I.N.) is stamped on the upper right side of the cowl top front panel.
VEHICLE IDENTIFICATION NUMBER

1. World manufacturer identifier code
KM - HMC Car manufactured & sold by HMC
KP - HMC Passenger car sold by MMSA
2H - HMC Passenger car manufactured by HMC-Hyundai Motor Company, Korea
2. Car Type
H - Passenger car (Manufactured by HMC)
M - Passenger car (Manufactured by HACI)
3. Drive line type

C - For LHD
4. Body Type
F - 4 Door sedan
5. Body style & version

1 - Standard (L)
2 - Deluxe (GL)
3 - Super deluxe (GLS)
6. Restraint type
1 - D:Active belt, P:Active belt
2 - D:Passive belt, P:Passive belt
3 - D:Active belt + A/Bag, P:Active or passive belt
4 - D:Active belt + A/Bag, P:Active belt + A/Bag
(D:Driver side, P:Passenger side)
7. Engine type
F-1997cc
T-2972ccV6
8. Check digit
Mathematically determined to validate frame numbers
9. Model year
V-1997
W-1998
10. Plant code

U - Ulsan plant
A - Asan plant
B - Bromont plant
11. Serial number 000001 through 999999

1998 Hyundai Sonata L4-2.0L Copyright © 2011, ALLDATA 10.40 Page 1
Vehicle: Application and ID
Engine Identification Number
ENGINE IDENTIFICATION PLATE
The engine identification plate is stamped at the right front side on the top edge of the cylinder block.
DESCRIPTION
Engine identification number consists of 11 digits.
1. Engine fuel
G : Gasoline
2. Engine range
4: In line 4 cycle 4 cylinder
6: In line 4 cycle 6 cylinder
3. Engine development order
A-Z
4. Engine capacity P: 1997cc T : 2972cc V6
5. Model year
V:1997 W:1998
6. Engine production sequence number
000001-999999
Powertrain Management: Application and ID
Federal Models
Engine ................................................................................................................................................................................... 2.0L (1,997 cc) DOHC L4
Ignition Timing .................................................................................................................................................................... 5°BTDC +/- 2° @ Idle [1]
Engine Management ...................................................................................................................................................... Engine Control Module (ECM)
EMISSION CONTROL DEVICES AND SYSTEMS
MFI/OBD II ........................................................................................................................................................ Computerized Engine Control System

PCV ................................................................................................................................................................... Positive Crankcase Ventilation System
SPK .............................................................................................................................................................. Electronic Spark Advance Control System
ECEGR........................................................................................................................................................................... Electronically Controlled EGR
EVAP ............................................................................................................................................................................... Evaporative Emission System
TWC .............................................................................................................................................................................................. One TWC Converter
CIS .......................................................................................................................................................................................... ECM Controlled Ignition
FR ............................................................................................................................................................................................................ Fuel Restrictor
HO2S ................................................................................................................................................................................ Two Heated Oxygen Sensors
MIL....................................................................................................................................................................................... Malfunction Indicator Light
[1] With timing connector grounded.

Powertrain Management: Application and ID
California Models
Engine ................................................................................................................................................................................... 2.0L (1,997 cc) DOHC L4
Ignition Timing .................................................................................................................................................................... 5°BTDC +/- 2° @ Idle [1]
Engine Management ...................................................................................................................................................... Engine Control Module (ECM)
EMISSION CONTROL DEVICES AND SYSTEMS
MFI/OBD II ........................................................................................................................................................ Computerized Engine Control System

PCV ................................................................................................................................................................... Positive Crankcase Ventilation System
SPK .............................................................................................................................................................. Electronic Spark Advance Control System
ECEGR........................................................................................................................................................................... Electronically Controlled EGR
EVAP ............................................................................................................................................................................... Evaporative Emission System
TWC & MCC .............................................................................................................................................................................. Two TWC Converters
CIS .......................................................................................................................................................................................... ECM Controlled Ignition
FR ............................................................................................................................................................................................................ Fuel Restrictor
HO2S ................................................................................................................................................................................ Two Heated Oxygen Sensors
MIL....................................................................................................................................................................................... Malfunction Indicator Light
[1] With timing connector grounded.

Engine: Testing and Inspection
Troubleshooting (Part 1 Of 2)
Troubleshooting (Part 2 Of 2)
Diagnosis By Symptom
Engine: Tools and Equipment
Special Tools (Part 1 Of 3)


Special Service Tools

Engine: Service and Repair
REMOVAL
1. Remove the battery.

2. Detach the air cleaner.
3. Disconnect the backup lamp and engine harness connectors.
4. For vehicles with 5-speed manual transaxles, disconnect the select control valve connector.
5. Disconnect the connectors for the generator harness and the oil pressure gauge wiring.
6. Drain the engine coolant.
7. For vehicles with automatic transaxles, disconnect transaxle oil cooler hoses.
NOTE: When disconnecting the hoses, make identification marks to avoid making mistakes when reconnecting them.
CAUTION: Be careful not to spill oil or fluid from hoses. Plug the openings to prevent foreign material from entering.
8. Disconnect the radiator upper and lower hoses on the engine side, then remove the radiator assembly.
9. Disconnect the high tension cable from the ignition coil section.
10. Disconnect the engine ground.
11. Disconnect the brake booster vacuum hose.
12. Remove the main fuel line, and the return and vapor hoses from the engine side.
CAUTION: To reduce the residual pressure in the hoses, refer to "Fuel filter."
13. Disconnect the heater hoses (inlet and outlet) on the engine side.
14. Disconnect the accelerator cable at the engine side.
15. For vehicles with manual transaxles, remove the clutch cable from the transaxle.
16. For vehicles with automatic transaxles, remove the control cable from the transaxle.
17. Disconnect the speedometer cable from the transaxle.
18. Disconnect the air conditioner compressor from the mounting bracket.
19. Jack up the vehicle.
20. Drain the transaxle oil (or fluid).

21. Disconnect the front exhaust pipe from the manifold.
NOTE: Use wire to suspend the exhaust pipe from the bottom of the vehicle.
22. For vehicles with manual transaxles, remove the shift control rod and extension rod.
23. Remove the lower arm ball joint bolts and the stabilizer bar at the point where it is mounted to the lower arm.
24. Remove the drive shafts from the transaxle case.
CAUTION:
- Plug the holes of the transaxle case to prevent entry of foreign material.
- Install new circlips on the drive shafts when reassembling.
25. Hang the lower arm and drive shaft from the body with a string.
26. Attach a cable to the engine, and use a chain hoist to lift the engine just enough to pull cable tight.
27. Remove the front roll stopper.
28. Separate the rear roll stopper.
29. Remove the engine mounting insulator bolts.
30. Remove the engine mounting bracket from the engine.
31. Slowly raise the engine (to the extent that the engine and transaxle weights are not applied to the mounting portions) and temporarily hold it
in the raised position.
CAUTION: Check that all cables, hoses, harnesses, connectors etc... are disconnected from the engine.
32. Remove the caps from inside the right fender shield and remove the transaxle mount bracket bolts.
33. Remove the left mount insulator bolt.
34. While directing the transaxle side downward, lift the engine and transaxle assembly up and out of the vehicles.
INSTALLATION
1. While checking the connections of the harnesses, pipes, hoses, etc..., and ensuring that none of them is being caught, damaged, etc..., install
the engine and transaxle assembly.
2. When the engine and transaxle assembly are in place, temporarily tighten the front roll stopper.
3. The front and rear center member rubber bushings and collars are different.
4. After the weight of the engine and transaxle assembly has been put on each insulator, tighten to specified torque.
5. Reassemble all of the components removed during disassembly. Be especially careful to properly secure all components, including fuel,
electrical and fluid pipe connections.
6. Refill the coolant and check for leaks.
7. Refill the transaxle fluid, test its operation, and check for leaks.
8. Check the operation of the transaxle control cable and accelerator cable. Adjust as necessary.
9. Check for proper operation of each of the various gauges.
Compression Check: Testing and Inspection
CHECKING COMPRESSION PRESSURE
1. Before checking compression, check the engine oil level. Also check that the starter motor and battery are all in normal operating condition.
2. Start the engine and wait until engine coolant temperature reaches 80 - 95°C (176 - 205°F).
3. Stop the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5. Crank the engine to remove any foreign objects in the cylinders.
6. Attach the compression gauge to the spark plug hole.
7. Depress the accelerator pedal to fully open the throttle.
8. Crank the engine and read the gauge.
Cylinder's compression at 250 - 400 rpm: 1.18 kPa (12.0 kg/cm2,171 psi)
9. Repeat steps 6 through 8 on all cylinders, ensuring the pressure differential for each of the cylinders is within the specified limit.
Pressure differential between cylinders: 100 kPa (1.0 kg/cm2, 14 psi)
10. If a cylinders compression or pressure differential is below the specification, add a small amount of oil through the spark plug hole, and
repeat steps 6 through 9.
1) If the addition of oil brings the compression up, there may be wear between the piston ring and cylinder wall
2) If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder head gasket are all possible
causes.
Spark plug: 20 - 30 Nm (200 - 300 kgs.cm, 14 - 22 ft. lbs.)

Camshaft: Testing and Inspection
1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or excessively worn, replace the camshaft.
Standard value:
Intake: 35.493 mm (1.3947 inch)
Exhaust: 34.200 mm (1.3858 inch)
Limit:
Intake: 34.993 mm (1.3777 inch)
Camshaft: Service and Repair
COMPONENTS
DISASSEMBLY
1. Disconnect the negative terminal from battery.

2. Drain the engine coolant.
3. Remove the breather hose between the air cleaner and the rocker cover.
4. Remove the air cleaner.
5. Remove the timing belt cover.
6. Remove the rocker cover, crank angle sensor.
7. Loosen the camshaft and sprocket bolts, then remove the camshaft sprockets.
8. Loosen the bearing cap bolts and remove the bearing caps, camshafts, rocker arms and lash adjusters.
INSPECTION
Rocker Arms
1. Check roller rotation. If it does not rotate smoothly or loose, replace it.
2. Check the roller. Replace if there are any dents, damage or evidence of seizure.
3. Check the valve contact surface for possible damage or seizure. Replace as necessary.
Camshafts
1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or excessively worn, replace the camshaft.
Standard value:
Intake: 35.493 mm (1.3947 inch)
Limit:
Intake: 34.993 mm (1.3777 inch)
REASSEMBLY
1. Install the camshafts on the cylinder head.
NOTE:
1) Apply engine oil to journals and cams of the camshafts.
2) The intake camshaft has a slit on its rear end for driving the crankshaft position sensor.
2. Install the bearing caps. Check the markings on the caps for intake/exhaust identification symbol.
L: Intake camshaft. R: Exhaust camshaft
3. Check that the camshaft can be easily turned by hand. After checking, remove the bearing caps and the camshafts, and then install the rocker
arms.
4. Make sure that the dowel pins on the camshaft sprocket end are located on the top.
5. Tighten the bearing caps to the specified torque in two or three steps as shown.
NOTE: Tighten the rocker arms uniformly.
Tightening torque
Rocker arm bolts: 19 - 21 Nm (190 - 210 kgs.cm, 14 - 15 ft. lbs.)
6. Using special tools, Camshaft Oil Seal Installer and guide (09221 - 21000, 09221 - 21100), press and fit the camshaft oil seal. Be sure to
apply engine oil to the external surface of the oil seal. Insert the oil seal along the camshaft front end and install by driving the installer with a
hammer until the oil seal is fully seated.
7. Install the camshaft sprockets to the specified torque.
Tightening torque
Camshaft sprocket bolts: 80 - 100 Nm (800 - 1000 kgs.cm, 58 - 72 ft. lbs.)
8. Install the rocker cover. Apply sealant as shown.
Tightening torque
Rocker cover bolts: 2.5 - 3.5 Nm (25 - 35 kg cm, 2 - 3 ft. lbs.)
Sealant
A portion: Threebond No. 10 or equivalent.
B portion: Threebond No.1212D or equivalent.
Bolt length x Diameter:

* 25mm x 6mm
** 20mm x 6mm
*** 15mm x 6mm
9. Install the spark plugs, center cover and the rubber as shown in the illustration.
10. Locate the dowel pin on the sprocket side of the intake cam shaft at the top.
Rocker Arm Assembly: Testing and Inspection
1. Check roller rotation. If it does not rotate smoothly or loose, replace it.
2. Check the roller. Replace if there are any dents, damage or evidence of seizure.
3. Check the valve contact surface for possible damage or seizure. Replace as necessary.
Cylinder Block Assembly: Testing and Inspection
DISASSEMBLY
Remove the cylinder head, timing belt train, front case, flywheel, Piston and crankshaft.
INSPECTION
Cylinder Block
1. Visually check the engine block for scores, rust and corrosion. Also check for cracks or any other defects. Repair or replace the block if
defective.
2. Measure cylinder bore with a cylinder gauge at three levels in directions of A and B.
- Level 1: No. 1 piston ring position with piston at TDC
- Level 2: Center of cylinder
- Level 3: Bottom of cylinder
3. If cylinder bores show more than specified out-of-round or taper, or if cylinder walls are badly scuffed or scored, rebore and hone engine
block, and fit with new, oversize piston and rings.
Standard value:
Cylinder bore: 85.00 - 85.03 mm (3.3465 - 3.3476 inch)
Out-of-roundness and taper of cylinder bore:
Maximum: 0.01 mm (0.0004 inch)
4. If cylinder top ridge is worn in stages, cut away with ridge reamer.
Piston service size and mark mm (inch)
5. Oversize pistons are available in four sizes.

6. To rebore the cylinder to oversize, keep the specified clearance between the oversize piston and the bore, and make sure that all pistons used
are of the same oversize. The standard measurement of the piston outside diameter is taken at a level 2 mm (0.08 inch) above the bottom of
the piston skirt and across the thrust faces.
Standard value:
Piston-to-cylinder wall clearance: 0.01 - 0.03 mm (0.0004 - 0.0012 inch)
7. Check for damage and cracks.

8. Check top surface for flatness. If excessive flatness is evident, grind to minimum limit or replace.
Standard valve:
Flatness of cylinder block surface: Max. 0.05 mm (0.0020 inch)
Engine block (New) height: 284 mm (11.18 inch)
Limit:
Flatness of cylinder block surface: 0.1 mm (0.0039 inch)
Overall height: -0.2 mm (-0.0079 inch)
NOTE: The cylinder block surface should be ground to within -0.2 mm (-0.0079 inch) even with the grind of cylinder head surface.
Boring Cylinder
1. Oversize pistons used should be determined based on the largest bore cylinder.
NOTE: Size mark is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

3. Based on the measured O.D., calculate the boring finish dimension.
Boring finish dimension = Piston O.D + 0.02 to 0.04 mm (0.0008 to 0.0016 inch) (clearance between piston and cylinder) - 0.02 mm
(0.008 inch) (honing margin inch)
4. Bore each of the cylinders to the calculated size.
CAUTION: To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order sequence.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
NOTE: When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to an oversize.
Balance Shaft: Service and Repair
REMOVAL
1. Remove front case.
2. Remove balance shafts from engine block. See: Engine Lubrication/Oil Pump/Service and Repair
INSTALLATION
Installation is the reverse of removal.
Connecting Rod: Service and Repair
DISASSEMBLY
Connecting Rod Cap
NOTE: Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for proper reassembly.
1. Remove the connecting rod cap nuts and then remove the caps and the big end lower bearing.
2. Push each piston-connecting rod assembly toward the top of the cylinder.
Piston Pin Removal & Installation Procedures
1. Use the special tools (09234-33001) to disassemble and reassemble the piston and connecting rod.
2. Place the proper insert in the fork of the tool. Insert the position between the connecting rod and the piston.
3. Insert the proper removal tool through the hole in the arch of the tool.
NOTE: Center the piston, rod and pin assembly with the removal arbor.
4. Press the piston pin out of the connecting rod.
5. Install proper pin guide (refer to application chart) through piston and into connecting rod. Hand and tap pin guide into piston for proper
retention. Drop piston pin into the other side of the piston.
NOTE: The pin guide centers the connecting rod in the piston. When the piston, connecting rod, piston pin and pin guide assembly are
positioned on the fork of the tool, the pin guide will also center this assembly in the tool. If too small a pin guide used, the piston assembly
will not be located centrally in the tool, and damage may occur to the fork and/or insert of the tool.
6. Install piston assembly onto fork assembly of tool. Tool will support connecting rod at the piston pinch Be sure to slide the piston assembly
onto the fork until the pin guide contacts the fork insert.
7. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the specified alpha-numeric setting
from the application chart is obtained. Turn knurled nut to lock numbered sleeve on shaft.
8. Insert the installing arbor through the hole in the arch of the tool. Press piston pin into the connecting rod until the sleeve on the installing
arbor contacts the top of the tool arch. The pin guide will fall out of the connecting rod as the piston pin is pressed inch
CAUTION: Do not exceed 5000 pounds of force when stopping the installing arbor sleeve against the arch.
INSPECTION
Piston and Piston Pins
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the piston requires replacement, its rings
should also be replaced.
3. Check the piston pin fit in the piston pin hole. Replace any piston and pin assembly that is defective. The piston pin must be smoothly
pressed by hand into the pin hole (at room temperature).
Piston Rings
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in a ring groove to measure the side
clearance. If the clearance still exceeds the service limit, replace the piston and rings together. If it is less than the service limit, replace only
the piston rings.
Standard value:
Piston ring side clearance: 0.03 - 0.07 mm (0.0012 - 0.0028 inch)
Limit:
Piston ring side clearance: 0.1 mm (0.004 inch)
2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently
pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring.
Piston Ring End Gap:

Standard value:
No.1: 0.25 - 0.40 mm (0.0098 - 0.0157 inch)
No.2: 0.35 - 0.50 mm (0.01775 - 0.0234 inch)
Oil ring side rail: 0.20 - 0.70 mm (0.0079 - 0.0276 inch)
Limit:
No.1: 0.8 mm (0.031 inch)
No.2: 0.8 mm ( 0.031 inch)
Oil ring side rail: 1.0 mm (0.040 inch)
Connecting Rods
1. When the connecting rod cap is installed, make sure that cylinder numbers marked on rod end cap at disassembly match. When a new
connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged at either end of the thrust faces, if it has a step wear in, or if the surface of the inside diameter of
the small end is severely rough.
REASSEMBLY
1. Install the spacer.
2. Install upper side rail. To install side rail, first put one end of side rail between piston ring groove and spacer, hold it down firmly, then press
down with your finger the portion to be inserted into groove as illustrated.
NOTE: Do not use piston ring expander when installing side rail.
3. Install lower side rail by same procedure as Step 2.

4. Using piston ring expander, install No.2 piston ring.
5. Install No. 1 piston ring.

6. Apply engine oil around piston and piston rings.
7. Position each piston ring end gap as far apart from neighboring gaps as possible. Make sure that gaps are not positioned in side rail thrust and
pin directions.
8. Hold piston rings firmly in a piston ring compressor as you insert them into cylinder.
9. Make sure that front mark of piston and front mark (identification mark) of connecting rod are directed toward front of engine.
10. When connecting rod cap is installed, make sure that cylinder numbers put on rod and cap at disassembly match.
11. When new connecting rod is installed, make sure that notches for holding bearing in place are on same side.
12. Tighten the connecting rod cap nuts.
Tightening torque:
Connecting rod cap nuts: 50 - 53 Nm (500 - 530 kgs.cm, 36 - 39 ft. lbs.)
13. Check connecting rod side clearance.
Standard value:
Standard value: 0.10 - 0.25 mm (0.004 - 0.0098 inch)
Limit: 0.4 mm (0.0157 inch)
Crankshaft: Service and Repair
DISASSEMBLY
1. Remove the timing belt train, front case, flywheel cylinder head assembly and oil pan.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
4. Mark the main bearing caps to permit reassembly in the original position and direction.
5. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order by cap number.
INSPECTION
Crankshaft
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check oil holes for clogging. Correct or replace any
defective part.
2. Inspect out-of-roundness and taper of crankshaft journal and pinch
Standard value:
Crankshaft journal O.D: 56.980 - 56.995 mm (2.2433 - 2.2439 inch)
Crankshaft pin O.D: 44.980 - 44.995 mm (1.7709 - 1.7715 inch)
Main Bearings and Connecting Rod Bearings

Visually inspect each bearing for peeling, melt, seizure and improper contact. Replace the defective bearings.
Oil Clearance Measurement
To check the oil clearance, measure outside diameter of the crankshaft journal and the crank pin and inside diameter of the bearing. The
clearance measurement is the difference between the measured outside and inside diameters.
Oil clearance:
Standard value:
Crankshaft main bearing: 0.02 - 0.05 mm (0.0008 - 0.0020 inch)
Connecting rod bearing: 0.02 - 0.05 mm (0.0008 - 0.0020 inch)
Limit:
Crankshaft main bearing: 0.1 mm (0.004 inch)
Connecting rod bearing: 0.1 mm (0.004 inch)
Plastigauge Method
Plastigauge may be used to measure the clearance.
1. Remove oil, grease and any other dirt from bearings and journals.
2. Cut plastigauge to the same length as the width of the bearing and place it in parallel with the journal, off oil holes.
3. Install the crankshaft, bearings, and caps. Tighten them to the specified torques. During this operation, do not turn the crankshaft. Remove
the caps. Measure the width of the plastigauge at the widest point using the scale printed on the gauge package. If the clearance exceeds the
repair limit, replace the bearing.
When installing a new crankshaft, be sure to use standard size bearings.
Oil Seal
Check front and rear oil seals for damage or worn lips. Replace any seat that is defective.
Bearing Caps
After installing the bearing caps, make sure the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace
crankshaft bearings.
Standard value: 0.05 - 0.18 mm (0.0020 - 0.0071 inch)

Limit: 0.25 mm (0.0098 inch)
Drive Plate
Replace deformed, damaged, or cracked drive plates.
Flywheel
1. Check the clutch disc contacting surface of the flywheel for damage and wear. Replace the flywheel if excessively damaged or worn.
2. Check the clutch disc contacting surface of the flywheel for run-out.
3. Limit:
Flywheel run-out: 0.13 mm (0.0051 inch)
4. Check the ring gear for damage, cracks and wear. Replace if necessary.
REASSEMBLY
1. Install grooved main bearing (upper bearing) on cylinder block side.

2. Install grooveless main bearing (lower bearing) on main bearing cap side.
3. Both upper and lower bearings for center are grooveless.
4. Install crankshaft. Apply engine oil to journal and pinch

5. Install caps with arrow mark directed toward front of engine. Cap number must be correct.
6. Tighten cap bolts to specified torque in sequence of center No.2, No.4, front and rear caps.
Tightening torque:
Main bearing cap bolts: 65 - 70 Nm ( 650 - 700 kgs.cm, 47 - 51 ft. lbs.)
7. Cap bolts should be tightened evenly in 4 to 5 stages before they are tightened to specified torque.
8. Make certain that crankshaft turns freely and has proper end play.
9. Using special tool, install oil seal in oil seal case.
10. Install the oil separator into the oil seal so that the oil hole in the separator is directed downward (arrow in illustration)
11. Install the new oil seal case gasket and oil seal case assembly.
12. Install the rear plate to the cylinder block.
13. Install the flywheel assembly and tighten the bolts to the specified torque.
Tightening torque:
Flywheel bolt: 130 - 140 Nm (1,300 - 1,400 kgs.cm, 94 - 101 ft. lbs.)
Cylinder Head Assembly: Testing and Inspection
Cylinder head
1. Check the cylinder head for cracks, damage and coolant leakage. If cracked, replace the cylinder head.
2. Remove scale, sealing compound and carbon. After cleaning oil passages, apply compressed air to ensure that passages are not clogged.
3. Check the cylinder head surface for flatness in the direction of A, B. as shown in illustration. If flatness exceeds service limit in any direction,
either replace the cylinder head, or lightly machine the cylinder head gasket surface.
Standard value:
Cylinder head surface flatness:
Less than 0.005 mm (0.002 inch)
Limit:
Cylinder head surface flatness: 0.1 mm (0.0040 inch)
Valves
1. Using a wire brush, clean the valve thoroughly.
2. Check each valve for wear, damage and distortion of head and stem at B. Repair or correct, if necessary. If stem end A is pitted or worn,
resurface as necessary. This correction must be limited to a minimum. Also resurface the valve face.
Replace the valve if the margin has decreased to less than the service limit.
Margin:
Standard value:
Intake: 1.0 mm (0.040 inch)
Exhaust: 1.5 mm ( 0.059 inch)
Limit:
Valve Springs
1. Check the valve spring free length and tension. If they exceed the service limit, replace the spring.
2. Using a square, test the squareness of each spring. If a spring is excessively out of square, replace it.
Valve Spring:
Standard value:
Free height: 48.3 mm (1.902 inch)
Load: 300N (66 lbs.) 40 mm (1.575 inch)
Out of square: Less than 1.5°
Limit:
Free height: -1.0 mm (-0.039 inch)
Out of square: 4°
Valve Guides
Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with the next oversize part.
Valve stem-to-guide clearance:

Standard value:
Intake: 0.020 - 0.047 mm (0.0008 - 0.0019 inch)
Exhaust: 0.050 - 0.085 mm (0.0020 - 0.0033 inch)
Limit:
Valve Seat Insert

Check the valve seat for evidence of overheating and improper contact with the valve face. Recondition or replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. if the valve guide is worn, replace it, then recondition the seat. Recondition the
valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
Cylinder Head Assembly: Service and Repair
COMPONENTS
DISASSEMBLY
Tightening Sequence
1. Using the special tool, Cylinder Head Bolt Wrench (09221 - 32001), remove the cylinder head bolts as shown in the illustration.
2. Using the special tool, Valve Spring Compressor (09222 - 28000, 09222 - 28100), remove the retainer lock. Next, remove the spring retainer,
valve spring, spring seat and valve.
NOTE: Keep these parts in order so they can be reinstalled in their original Positions.
3. Remove the valve stem seals with pliers, and discard.
NOTE: Do not reuse the valve stem seals.
INSPECTION
Cylinder head
1. Check the cylinder head for cracks, damage and coolant leakage. If cracked, replace the cylinder head.
2. Remove scale, sealing compound and carbon. After cleaning oil passages, apply compressed air to ensure that passages are not clogged.
3. Check the cylinder head surface for flatness in the direction of A, B. as shown in illustration. If flatness exceeds service limit in any direction,
either replace the cylinder head, or lightly machine the cylinder head gasket surface.
Standard value:
Cylinder head surface flatness:
Less than 0.005 mm (0.002 inch)
Limit:
Cylinder head surface flatness: 0.1 mm (0.0040 inch)
Valves
1. Using a wire brush, clean the valve thoroughly.
2. Check each valve for wear, damage and distortion of head and stem at B. Repair or correct, if necessary. If stem end A is pitted or worn,
resurface as necessary. This correction must be limited to a minimum. Also resurface the valve face.
Replace the valve if the margin has decreased to less than the service limit.
Margin:
Standard value:
Limit:
Valve Springs
1. Check the valve spring free length and tension. If they exceed the service limit, replace the spring.
2. Using a square, test the squareness of each spring. If a spring is excessively out of square, replace it.
Valve Spring:
Standard value:
Free height: 48.3 mm (1.902 inch)
Load: 300N (66 lbs.) 40 mm (1.575 inch)
Out of square: Less than 1.5°
Limit:
Free height: -1.0 mm (-0.039 inch)
Out of square: 4°
Valve Guides
Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with the next oversize part.
Valve stem-to-guide clearance:

Standard value:
Intake: 0.020 - 0.047 mm (0.0008 - 0.0019 inch)
Exhaust: 0.050 - 0.085 mm (0.0020 - 0.0033 inch)
Limit:
Valve Seat Insert
Check the valve seat for evidence of overheating and improper contact with the valve face. Recondition or replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. if the valve guide is worn, replace it, then recondition the seat. Recondition the
valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
REASSEMBLY
NOTE:
1) Clean each part before assembly.
2) Apply engine oil to sliding and rotating parts.
1. After installing the spring seat, fit the stem sea' onto the valve guide.
To install, fit the seal in by lightly tapping the Special Tool, Valve Stem Oil Seal Installer.
The seal is installed in the specified position by means of the special tool. Incorrect installation of the seal will adversely affect the lip l.D.
and eccentricity, resulting in oil leaking down the valve guides. Therefore, when installing, be careful not to twist the seal. Do not reuse old
stem seals.
2. Apply engine oil to each valve. Insert the valves into the valve guides. Avoid using force when inserting the valve into the seal. After
insertion, check to see if the valve moves smoothly.
3. Install springs and spring retainers. Valve springs should be installed with the enamel coated side toward the valve spring retainer.
4. Using the special tool, Valve Spring Compressor, remove the retainer lock. Next, remove the spring retainer, valve spring, spring seat and
valve.
NOTE: Keep parts in order so they can be reinstalled in their original positions.
5. Clean all cylinder block and cylinder head gasket surfaces.

6. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket, and do not reuse the old cylinder head
gasket.
Tightening Sequence
7. Using the special tool, Cylinder Head Bolt Wrench (0922132001), install the cylinder head bolts as shown in the illustration
Cylinder head bolt (cold engine): 90 - 100 Nm (900 - 1000 kgs.cm, 65 - 72 ft. lbs.)
LASH ADJUSTERS CHECK

If abnormal noise is heard from the lash adjusters (tappets), check as follow;
1. While installed to the cylinder head, press the part where the rocker arm contacts the lash adjuster at the very top. If the adjuster is normal,
the part pressed will feel very hard.
2. If it easily moves all the way downward when pressed, there is a malfunction of the lash adjuster and it should be replaced with a new one.
3. If it feels spongy or elastic, probably oil with air mixed in it has entered the lash adjuster, so follow the steps below:
- Check whether the amount of oil is too much or is not enough.
- Check whether the cause of air becoming mixed into the oil is a damaged oil screen or oil screen gasket. After repairing the cause of the
air leak, warm up the engine and then drive the vehicle at low speed for a while.
4. Stop the engine and leave it off for a few minutes, then re-start the engine and drive at low speed. Re-start this procedure several times during
the course of about one hour so as to remove the air from the oil.
Fuel Pressure Release: Service and Repair
1. Reduce the internal pressure of the fuel pipes and hoses by the following procedures.
- Disconnect the fuel pump harness connector in the rear seat side.
- Start the engine and, after it stops by itself, turn the ignition switch to the OFF position.
- Disconnect the battery negative (-) terminal. Connect the fuel pump harness connector.
2. Disconnect the fuel high pressure hose at the fuel line side.
CAUTION: Cover the pipe connection with a shop towel to prevent fuel from splashing (caused by residual pressure in the fuel line).
Valve Guide: Service and Repair
Valve Guide
The valve guide is installed using a press fit. Using a Valve Guide Installer (09222-28400, 09222-21200) or suitable tool, replace the valve guide
described in the following procedure.
1. Using the Valve Guide installer push rod, push the valve guide out toward the cylinder block with a press.
2. Machine the valve guide insert hole in the cylinder head to the specified oversize of the new valve guide.
3. Using the Valve Guide Installer or suitable tool, press and fit the valve guide. Using the valve guide installer makes it possible to press and fit
the valve guide to a predetermined height. Install the valve guide from the top of the cylinder head. Note that intake and exhaust valve guides
differ in length (45.5mm [1.791 in] for intake and 50.5mm [1.988in.] for exhaust).
4. After installing the valve guides, insert new valves and check the clearance.
5. Whenever valve guides are replaced, check for valve-to-seat contact, and recondition the valve seats as necessary.
Valve guide oversizes

Valve Seat: Service and Repair
REPLACEMENT
Valve Seat
1. Any valve seat insert that has been worn over the service limit should be removed at normal temperature after cutting away most of the insert
wall, using valve seat cutters, as shown.
2. After removing the seat insert, machine the seat insert bore using a reamer or a cutter. Cut to the size shown in the table.
3. Heat the cylinder head to about 250°C (480°F) and press in the oversize seat insert. The oversize seat insert should be at normal room
temperature for installation. After installing a new valve seat insert, resurface the valve seat using the same procedure described in "Valve
Seat Insert" (next).
Valve seat insert oversizes

Drive Belt: Testing and Inspection
1. Press the V-belt applying a pressure of 98 N (10 kg, 22 lbs.) at the specified point, and measure the deflection to confirm that it is within the
standard value range.
Standard value:
V-belt deflection: 7 - 10 mm (0.28 - 0.39 inch)
2. To adjust the belt tension, loosen the tensioner mounting nut and move the tensioner to obtain the standard value (V-6 ENG.).
3. To adjust the belt tension, loosen the oil pump mounting bolts, move the oil pump, and then retighten the bolts (DOHC ENG.).
Drive Belt: Adjustments
1. Check that the belts are not damaged and are properly fit into the pulley grooves.
CAUTION:
1. When installing the V-ribbed belt, check that the V-ribs are properly in alignment.
2. If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact surface, and check the pulley for
scoring. Also check for the proper belt deflection measurement.
2. Apply 100 N (22 lbs.) force to the belt back midway between the pulleys as shown in the illustration, measure the amount of deflection with
a tension gauge.
Standard value: 2.0L engine

Standard value: 3.0L engine
NOTE:
1. The belt tension must be measured between the specified pulleys.
2. When a new belt is installed, adjust the tension to the center of the standard range indicated under "New And then let the engine idle for 5
minutes or more, and check the standard value indicated under "Inspection".
3. When adjusting a belt which has been used or a belt newly installed after 5 minutes or more of operation, refer to the standard value
indicated under "Used".
4. Refer to the standard value indicated under "Inspection" for periodic inspections.
Adjustment
1. Loosen the tension pulley fixing bolt A.
2. Adjust the belt deflection with adjustment bolt B.
3. Tighten the fixing bolt A.
4. Re-check the belt deflection and re-adjust, if necessary.
NOTE
Before re-checking, crank the engine one or more revolutions.
Type A tension gauge

Do not let the dial section of the tension gauge contact other objects during measurement.
Type B tension gauge

1. When measuring, be sure to turn reset button in the arrow direction to set the gauge needle to the RESET position.
2. If the tension gauge is removed from the belt, the needle will still indicate the tension. Read the tension after removing the gauge.
Engine Mount: Service and Repair
COMPONENTS
REMOVAL
Attach an engine hoist to the engine hooks, and raise the engine just enough so there is no pressure on the insulators.
Engine Mounting
1. Remove the engine mount insulator bolts.

2. Remove the engine mount bracket from the engine.
Transaxle Mounting
1. For vehicles with a 5-speed manual transaxle, remove the select control valve.
2. Remove the transaxle mount bolt.

3. Detach the cap from inside the right fender shield. Remove the transaxle mounting bolts.
4. Remove the transaxle bracket.
Front Roll Stopper
Remove the front roll stopper bracket from the center member.
Rear Roll Stopper

1. Remove the bolt from the rear roll stopper.

2. Remove the rear roll stopper from the crossmember.
Inspection Items
Engine Lubrication: Service and Repair
CHANGING ENGINE OIL
1. Run the engine until it reaches normal operating temperature.
2. Stop the engine.
3. Remove the oil filler cap (on rocker cover) and the drain plug (on the oil pan). Drain the engine oil.
4. Re-install and tighten the drain plug to the specified torque.
Tightening torque
Drain plug: 35 - 45 Nm (350 - 450 kgs.cm, 25 - 33 ft. lbs.)
5. Fill the crankcase with fresh engine oil through the oil filler cap opening.
Capacity:
Dry fill: 4.3 lit (4.5 U.S.Qts., 3.8 Imp.Qts.)
Drain and refill:
Without oil filter: 3.7 lit (3.91 U.S.Qts., 3.25 Imp.Qts.)
With oil filter: 4.0 lit (4.23 U.S.Qts., 3.51 Imp.Qts.)
CAUTION: Do not overfill the crankcase. This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.

7. Start and run the engine.
8. Stop the engine and then check the oil level. Add oil if necessary.
Engine Oil: Service and Repair
CHANGING ENGINE OIL
1. Run the engine until it reaches normal operating temperature.
2. Stop the engine.
3. Remove the oil filler cap (on rocker cover) and the drain plug (on the oil pan). Drain the engine oil.
4. Re-install and tighten the drain plug to the specified torque.
Tightening torque
Drain plug: 35 - 45 Nm (350 - 450 kgs.cm, 25 - 33 ft. lbs.)
5. Fill the crankcase with fresh engine oil through the oil filler cap opening.
Capacity:
Dry fill: 4.3 lit (4.5 U.S.Qts., 3.8 Imp.Qts.)
Drain and refill:
Without oil filter: 3.7 lit (3.91 U.S.Qts., 3.25 Imp.Qts.)
With oil filter: 4.0 lit (4.23 U.S.Qts., 3.51 Imp.Qts.)
CAUTION: Do not overfill the crankcase. This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.

7. Start and run the engine.
8. Stop the engine and then check the oil level. Add oil if necessary.
Oil Filter: Service and Repair
REPLACEMENT OIL FILTER
All Hyundai Motor Company engines are equipped with a high quality, throw-away oil filter. This filter is recommended as a replacement filter
on all vehicles. The quality of replacement filters varies considerably.
Only high quality of replacement filters should be used to assure the most efficient service. Make sure that the rubber gasket from the old oil
filter is completely removed from the mating surface on the engine block, before installing the new filter.
REPLACING OIL FILTER
1. Use a filter wrench to remove the oil filter

2. Before installing the new oil filter on the engine, apply clean engine oil of the surface of the rubber gasket.
3. Tighten the oil filter of the specified torque.
Oil filter: 17 - 25 Nm (170 - 250 kgs.cm, 12 - 18 ft. lbs.)
4. Start and run the engine and check for engine oil leaks.
5. After stopping the engine, check the oil level and add oil as necessary.
Oil Pressure Switch: Testing and Inspection
ENGINE OIL PRESSURE SWITCH
1. Check that there is continuity between terminal and ground with the engine stopped.
2. Check that there is no continuity between terminal and ground with the engine running.
3. If operation is not as specified, replace the switch.
4. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector.
5. Turn the ignition switch ON, check that the warning lamp lights up.
If the warning lamp does not light up, test the bulb or inspect wire harness.
Oil Pressure Switch: Service and Repair
OIL PRESSURE SWITCH
1. If "OIL PRESSURE" indicating lamp lightens when ignition switch is set to "ON" and goes out when engine is started and runs at idle, then
everything is in order. If "OIL PRESSURE" lamp does not lighten when ignition switch is set to "ON," check switch, lamp and wiring.
2. If there is current flow when ignition switch is set to "ON" and if there is no current flow when engine is running at idle, switch is good.
If switch is good, check lamp and wiring.
Pressure of oil switch operation: 14.71 - 29.42 kPa (0.15 - 0.3 kg/cm2,2.1 - 4.3 psi)
3. Using the special tool (09260-32000), tighten the switch to the specified torque.
NOTE: Do not overtorque the oil pressure switch
Oil pressure switch and sender assembly: 8 - 12 Nm (80 - 120 kgs.cm, 5.8 - 8.7 ft. lbs.)
INSPECTION
Oil Pressure Switch
1. Use an ohmmeter to check the continuity between the terminal and the body. If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is
pushed, replace it.
3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating properly. Check to see that air
doesn't leak. If air leaks, the diaphragm is broken. Replace the switch.
INSTALLATION
1. Apply sealant to threaded portion.
2. Using special tool (09260-32000), tighten switch to specified torque.
Tightening torque:
Oil pressure switch: 8 - 12 Nm (80 - 120 kgs.cm, 5.8 - 8.7 ft. lbs.)
Oil Pump: Service and Repair
COMPONENTS
REPLACEMENT AND INSTALLATION OF COUNTER BALANCE SHAFT
Replacement
1. Using special tool, remove the right counter balance shaft front bearing from the cylinder block.
2. Using special tool, remove the right counter balance shaft rear bearing from the cylinder block.
3. Using special tool, remove the left counter balance shaft rear bearing from cylinder block. At this time, install special tool on front surface of
cylinder block to hold bearing puller.
4. Using special tool, install the left counter balance shaft rear bearing to the cylinder block.
NOTE:
1) Apply engine oil to the rear bearing outer circumference and bearing hole in cylinder block.
2) The left rear bearing has no oil holes.
5. Using special tool, install the right counter balance shaft rear bearing to the cylinder block
NOTE:
1) Apply engine oil to outer surface of bearing.
2) Make sure that bearing oil hole is aligned with oil hole of cylinder block.
6. Using special tool, install the right counter balance shaft front bearing to the cylinder block.
NOTE: Make sure that bearing oil hole is aligned with cylinder block oil hole.
DISASSEMBLY
1. Remove the timing belt.

2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen and gasket.
5. Remove the relief plunger and gasket, then remove the bracket relief spring and relief valve from the oil filter.
6. Remove the oil pressure switch.
7. Remove the oil filter bracket and gasket.

8. Using the special tool, remove the plug cap from the oil pump portion of the front case
9. Remove the left side cylinder block plug and insert a screw driver with an 8 mm (0.32 inch) diameter shaft into plug hole. Screwdriver shaft
must be inserted more than 60 mm (2.4 inch)
10. Remove the oil pump driven gear and left counter balance shaft retaining bolt.
11. Remove the front case mounting bolts and remove front case assembly and gasket.
12. Remove the two counter balance shafts from the cylinder block.
13. Remove the oil pump cover from the front case.
14. Remove the oil pump gears from front case.
Front Case
1. Check oil holes for clogging. Clean holes if necessary.
2. Check counter balance shaft front bearing section for wear, damage and seizure. If there is anything wrong with the section, replace the front
case.
3. Check the front case for cracks and other damage. Replace cracked or damaged front case.
Counter Balance Shaft

Check journals for wear or seizure.

If excessive wear or seizure is evident, check the bearing.
If necessary, replace counter balance shaft bearing or both.
Oil Seal
1. Check the oil seal lip for wear and damage. Replace oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace oil seal if necessary.
Oil Pressure Switch
1. Use an ohmmeter to check the continuity between the terminal and the body. If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is
pushed, replace it.
3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating properly. Check to see that air
doesn't leak. If air leaks, the diaphragm is broken. Replace the switch.
Oil Pump
Fig. 12 Measuring Oil Pump Gear Tip Clearance
1. Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness.
Fig. 13 Measuring Oil Pump Gear Side Clearance
2. Ensure that there is no ridge wear on the contact surface between the front case and gear surface of the oil pump cover.
3. With the drive and driven gears installed into the front case, measure the tip clearance of the gears.
Gear tip clearance:

Standard valve:
Drive gear: 0.16 - 0.21 mm (0.0063 - 0.0083 inch)
Driven gear: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Limit:
Drive gear: 0.25 mm (0.0098 inch)
Driven gear: 0.25 mm (0.0098 inch)
4. Check the side clearance.
Side clearance:
Standard value:
Drive gear: 0.08 - 0.14 mm (0.0031 - 0.0055 inch)
Driven gear 0.06 - 0.12 mm (0.0024 - 0.0047 inch)
Limit:
Drive gear: 0.25 mm (0.0098 inch)
Driven gear: 0.25 mm (0.0098 inch)
REASSEMBLY
1. Apply engine oil to the gear and align the two timing marks.
2. Using the special tool, Crankshaft Front Oil Seal Installer (09214-32000), install the crankshaft front oil seal into the front case.
3. Set the special tool (09214-32100) on the front end of crankshaft and apply a thin coat of engine oil to outer circumference of the special tool
to install the front case.
4. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the
filter bracket).
5. Install the front case assembly with a new gasket. Tighten bolts to the specified torque.
Tightening torque:
Front case assembly (bolt length below head): 27 - 34 Nm (270 - 340 kgs.cm, 20 - 25 ft. lbs.)
Front case assembly (all except bolt length below head): 20 - 27 Nm (200 - 270 kgs.cm, 14 - 20 ft. lbs.)
All except oil filter bracket bolts: 15 - 22 Nm ( 150 - 220 kgs.cm, 11 - 16 ft. lbs.)
6. Insert screwdriver through plug hole in left side of cylinder block to check shaft is in position, and tighten.
7. Install a new O-ring to the groove of the front case.
Fig. 29 Applying Sealant To Oil Pan
8. Using special tool, install the plug case and tighten to specified torque.
9. Apply sealant into the groove of the pan flange as shown.
NOTE:
1) Apply sealant approximately 4 mm (0.16 inch) in thickness.
2) After application of sealant, install oil pan within 15 minutes. List what type of sealant to use.
10. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque:
Oil pan bolt: 6 - 8 Nm (60 - 80 kgs.cm, 4 - 6 ft. lbs.)
11. Using the special tool, install the oil pressure switch after applying sealant to the threaded area.
Sealant: Threebond 1104 or equivalent
NOTE: Do not overtorque the oil pressure switch.
Tightening torque:
Oil pressure switch: 8 - 12 Nm (80 - 120 kgs.cm, 6 - 9 ft. lbs.)
Intake Manifold: Service and Repair
DISASSEMBLY
1. Disconnect the high pressure fuel hose connection after relieving pressure in the fuel pipe line to prevent fuel overflow. (Refer to "Fuel
System.")
2. Remove the delivery pipe with the fuel injectors and pressure regulator attached.
CAUTION: Do not drop the injectors when removing the delivery pipe.
INSPECTION
1. Check all parts for damage or cracking.
2. Check for obstruction of the vacuum outlet port and the gas passage.
REASSEMBLY
Do not drop the injector when installing the delivery pipe.

Timing Belt: Testing and Inspection
1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper. Do not clean
with solvent.
2. When the engine is overhauled or belt tension adjusted, carefully check the belt. If any of the following flaws are evident, replace the belt.
Timing Belt: Service and Repair
COMPONENTS
DISASSEMBLY
CAUTION: THE 2.0 L IS AN INTERFERENCE ENGINE
1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt.
2. Remove the timing belt cover.
3. Turn the crankshaft clockwise and align the timing marks to bring the No. 1 cylinder to compression top-dead-center position.
At this time the timing marks of the camshaft sprocket and the upper surface of the cylinder head should coincide, and the dowel pin of the
camshaft sprocket should be at the upper side.
Remove the auto tensioner.
CAUTION: Rotate the crankshaft clockwise.

4. Remove the timing belt.
NOTE: If the timing belt is reused, make an arrow mark indicating the turning direction (or the front of the engine) to make sure that the
belt is reinstalled in the same direction as before.
5. Remove the camshaft sprockets.
NOTE: Be careful not to damage the cylinder head with the wrench.
6. When the oil pump sprocket nut is removed, first remove the plug at the left side of the cylinder block and insert a screwdriver to keep the
left counter balance shaft in position. Use a screwdriver with a shaft measuring 8 mm (0.3inch) in diameter which can be inserted being more
than 60 mm (2.36 inch)
7. Remove the oil pump sprocket retaining nut and the oil pump sprocket.
8. Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand.
9. Next, remove tensioner "B" and timing belt "B."
CAUTION: After timing belt "B" has been removed, do not attempt to loosen the bolt while holding sprocket with pliers, etc..
10. Remove the crankshaft sprocket "B" from crankshaft.
INSPECTION
Sprockets
1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as
necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation and check for play or noise. Replace as necessary.
Auto Tensioner
1. Check the auto tensioner for leaks and replace as necessary.

2. Check the rod end for wear or damage and replace as necessary.
3. Measure the rod protrusion. If it is out of specification, replace the auto tensioner.
Rod protrusion: 12 mm (0.47 inch)
4. Using a vise soft jaw, push in the auto tensioner rod. If the rod can be easily retracted, replace the auto tensioner. You should feel a fair
amount of resistance when pushing the rod inch
CAUTION:
1) Clamp the auto tensioner in the vise so that it is level. Use soft jaws in the vise to avoid damaging the auto tensioner.
2) If the plug is at the bottom of the auto tensioner, insert a plain washer to prevent directly contacting the plug with the vise.
Timing Belt
1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper. Do not clean
with solvent.
2. When the engine is overhauled or belt tension adjusted, carefully check the belt. If any of the following flaws are evident, replace the belt.
REASSEMBLY
1. Install crankshaft sprocket "B" into crankshaft.
CAUTION: Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken belt could result.
2. Lightly apply engine oil to the outer surface of spacer, and then install spacer to the right counter balance shaft. Be sure to install in the
direction shown in illustration.
3. Install counterbalance shaft sprocket onto right counterbalance shaft, then finger tighten flange bolt.
4. Align timing mark on each sprocket with corresponding timing mark on the front case.
5. When timing belt "B" is installed, make certain that tension side has no slack.
Install tensioner "B" with center of pulley located on the left side of mounting bolt and with pulley flange directed toward front of engine.
Align timing mark on the right counter balance shaft sprocket with the timing mark on the front case.
6. Lift tensioner "B" to tighten timing belt "B" so that its tension side will be pulled tight. In this condition, tighten bolt to secure tensioner "B".
When bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be overtightened.
7. Check to ensure that timing marks are in alignment.

8. Check to ensure that when center of span on the tension side is depressed with index finger in direction of arrow, deflection of belt is within
specification.
Standard value:
Belt deflection: 5 - 7 mm (0.2 - 0.3 inch)
9. Install flange and crankshaft sprocket onto crankshaft. Be sure to install in the direction shown in illustration.
CAUTION: Pay attention to direction of flange. If it is installed in wrong direction, a broken belt could result.
10. Insert screwdriver through plug hole in left side of cylinder block to keep shaft in position.
11. Install the oil pump sprocket, and tighten the nut to the specified torque.
12. Install the camshaft sprocket and tighten the bolt to the specified torque.
Tightening torque:
Camshaft sprocket: 80 - 100 Nm (kgs.cm, 58 - 72 ft. lbs.)
13. Install the auto tensioner.
CAUTION: Leave the wire installed in the auto tensioner.
NOTE: If the auto tensioner rod is in its fully extended position, reset it as follows.
1) Clamp it in a vise with soft jaws in a level position. Apply a plain washer if there is a plug at the bottom of the auto tensioner.
2) Push in the rod slowly with the vise until the set hole "A" in the rod is aligned with set hole "B" in the cylinder.
14. Install the tensioner pulley onto the tensioner arm. Locate the pinhole in the tensioner pulley shaft to the left of the center bolt, then finger
tighten the center bolt.
CAUTION: Leave the wire installed in the auto tensioner.
15. Turn the two sprockets so that their dowel pins are on top. Then, align the timing marks facing each other with the top surface of the cylinder
head.
NOTE: The same camshaft sprocket is used for the intake and exhaust camshafts and is provided with two timing marks. When the sprocket
is mounted on the exhaust camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake camshaft sprocket, use
the one on the left with the dowel pin hole on top.
16. Align the crankshaft sprocket timing marks.
17. Align the oil pump sprocket timing marks.
18. Install the timing belt around the tensioner pulley and crankshaft sprocket. Secure the timing belt onto the tensioner pulley with your left
hand.
19. Pulling the belt with your right hand, install it around the oil pump sprocket.
20. Install the belt around the idler pulley.
21. Install it around the intake camshaft sprocket.
22. Turn the exhaust camshaft sprocket one tooth clockwise to align its timing mark with the cylinder head top surface [see illustration in step
15]. Then, pulling the belt with both hands, install it around the exhaust camshaft sprocket.
23. Gently raise the tensioner pulley as shown by the arrow, so that the belt does not sag. Temporarily tighten the center bolt.
24. After turning the crankshaft 1/4 turn counterclockwise, turn it clockwise to move the No. 1 cylinder to top dead center.
25. Loosen the center bolt, then, as shown in the illustration, attach the special tool and a torque wrench and apply a torque of 2.6-2.8 Nm
(1.88-2.03 Ft lbs.). If the body interferes with the special tool and the torque wrench, use a jack to slightly raise the engine assembly.
NOTE: Use a torque wrench measuring within a range of 0-3 Nm (0 - 2.2 Ft lbs.).
26. Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification. Screw the special tool into the
engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool a bit more and remove the
set wire attached to the auto tensioner.
27. Remove the special tool.

28. Rotate the crankshaft two complete turns clockwise and leave it for about 15 minutes. Then, measure the auto tensioner protrusion "A"
(distance between the tensioner arm and auto tensioner body) to ensure that it is up to specification.
Standard value:
Auto tensioner protrusion A: 3.8 - 4.5 mm (015 - 0.18 inch)
If it is out of specification, repeat steps 24 through 28 until the specified value is obtained.
NOTE: If the clearance "A" between the tensioner arm and the auto tensioner body cannot be measured (when the engine is mounted on the
vehicle, for example), the following alternative method may be used.
1) Screw in the special tool until its end makes contact with the tensioner arm.
2) Screw in the special tool a bit more to retract the auto tensioner push rod while counting the number of turns the tool makes to bring the
tensioner arm into contact with the auto tensioner body.
Make sure that the number of turns the special tool makes conforms to the standard value.
Standard value: 2.5 - 3 turns

29. Install the rubber plug to the timing belt rear cover.
30. Install the timing belt lower cover and the timing belt upper cover.
Timing Belt Tensioner: Testing and Inspection
1. Check the auto tensioner for leaks and replace as necessary.

2. Check the rod end for wear or damage and replace as necessary.
3. Measure the rod protrusion. If it is out of specification, replace the auto tensioner.
Rod protrusion: 12 mm (0.47 inch)
4. Using a vise soft jaw, push in the auto tensioner rod. If the rod can be easily retracted, replace the auto tensioner. You should feel a fair
amount of resistance when pushing the rod inch
CAUTION:
1) Clamp the auto tensioner in the vise so that it is level. Use soft jaws in the vise to avoid damaging the auto tensioner.
2) If the plug is at the bottom of the auto tensioner, insert a plain washer to prevent directly contacting the plug with the vise.
Water Pump: Service and Repair
COMPONENTS
DISASSEMBLY
1. Drain the coolant and disconnect the radiator outlet hose and engine coolant bypass hose from the engine coolant pump.
2. Remove the drive belt and engine coolant pump pulley.
3. Remove the timing belt covers and the timing belt tensioner.
4. Remove the engine coolant pump mounting bolts, then remove the generator brace.
5. Remove the engine coolant pump assembly from the cylinder block.
INSPECTION
1. Check the engine coolant pump for cracks, damage or wear. Replace the engine coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise, and sluggish rotation. Replace the engine coolant pump assembly if necessary.
3. Check the seal unit for leaks. Replace the engine coolant pump assembly if necessary.
4. Check for engine coolant leakage. If engine coolant leaks from hole "A," seal unit is defective. Replace engine coolant pump assembly.
REASSEMBLY
1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.
2. Install the new O-ring onto the groove on the front end of the engine coolant pipe, then wet the O-ring with engine coolant. Do not apply oil
or grease.
3. Install new engine coolant pump gasket and engine coolant pump assembly. Tighten the bolts to specified torque.
Engine coolant pump to cylinder block:

Tightening torque:
Headmark"4" bolt: 12 - 15 Nm (120 - 150 kgs.cm, 9 - 11 ft lbs)
Headmark"7" bolt: 20 - 27 Nm (200 - 270 kgs.cm, 14 - 20 Ft lbs)
4. Install the timing belt tensioner and timing belt. Adjust the timing belt tension, then install the timing belt covers.
5. Install the engine coolant pump pulley and drive belt, then adjust the belt tension.
6. Refill the coolant.
7. Run the engine and check for leaks.
Cooling System: Service and Repair
COOLANT LEAK CHECK
1. Loosen the radiator cap.
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 150 kPa (21 psi, 1.53 kg/cm2) pressure. Hold for two minutes in that
condition, while checking for leakage from the radiator, hoses or connections.
CAUTION:
1) Radiator coolant may be extremely hot. Do not open the system while hot, or scalding water could spray out causing personal injury.
Allow vehicle to cool before servicing this system.
2) Be sure to completely clean away any moisture from the places checked.
3) When the tester is removed, be careful not to spill any coolant from it.
4) Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator.
4. If there is leakage, repair or replace the appropriate part.
SPECIFIC GRAVITY TEST
1. Measure the specific gravity of the coolant with a hydrometer.

2. Measure the coolant temperature, and calculate the concentration from the relation between the specific gravity and temperature. Use the
following table for reference.
Relation between coolant concentration and specific gravity
Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20°C (68°F)
CAUTION: If the concentration of the coolant is below 30%, the anticorrosion property will be adversely affected. In addition, if the
concentration is above 60%, both the anti-freeze and engine cooling properties will decrease, adversely affecting the engine. For these
reasons, be sure to maintain the concentration level within the specified range. Do not mix brands of coolant.
Recommended Coolant
Coolant: Service and Repair
COOLANT LEAK CHECK
1. Loosen the radiator cap.
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 150 kPa (21 psi, 1.53 kg/cm2) pressure. Hold for two minutes in that
condition, while checking for leakage from the radiator, hoses or connections.
CAUTION:
1) Radiator coolant may be extremely hot. Do not open the system while hot, or scalding water could spray out causing personal injury.
Allow vehicle to cool before servicing this system.
2) Be sure to completely clean away any moisture from the places checked.
3) When the tester is removed, be careful not to spill any coolant from it.
4) Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator.
4. If there is leakage, repair or replace the appropriate part.
SPECIFIC GRAVITY TEST
1. Measure the specific gravity of the coolant with a hydrometer.

2. Measure the coolant temperature, and calculate the concentration from the relation between the specific gravity and temperature. Use the
following table for reference.
Relation between coolant concentration and specific gravity
Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20°C (68°F)
CAUTION: If the concentration of the coolant is below 30%, the anticorrosion property will be adversely affected. In addition, if the
concentration is above 60%, both the anti-freeze and engine cooling properties will decrease, adversely affecting the engine. For these
reasons, be sure to maintain the concentration level within the specified range. Do not mix brands of coolant.
Recommended Coolant
Coolant Line/Hose: Service and Repair
COMPONENTS
INSPECTION
Check the engine coolant pipe and hose for cracks, damage, and restrictions. Replace if necessary.
REASSEMBLY
Fit O-ring in the groove provided at engine coolant inlet pipe end. Wet the periphery of the O-ring and inlet engine coolant inlet pipe.
NOTE:
1) Do not apply oils or greases to engine coolant pipe O-ring.
2) Keep the engine coolant pipe connections free of sand, dust, etc...
3) Insert engine coolant pipe until its end bottoms.
Radiator Cooling Fan Motor: Service and Repair
COMPONENTS
DISASSEMBLY
1. Disconnect the ground cable from battery cable.

2. Disconnect the connectors from the fan motor and the harness from shroud.
3. For vehicles with automatic transaxle, remove the oil cooler hose from the shroud.
4. Remove the shroud mounting four bolts.
5. Remove the shroud with the fan motor.
6. Remove the fan mounting clip and detach the fan from fan motor.
7. Remove the three screws and detach the fan motor.
INSPECTION
Radiator Fan Motor
Fig. 2 Radiator Fan Motor Terminal Identification
1. Check to be sure that the radiator fan rotates when battery voltage is applied between the terminals (as shown in the figure).
2. Check to see that abnormal noises are not produced while the motor is turning.
REASSEMBLY
1. Installation is in the reverse order of removal procedures.
CAUTION:
1) Make sure the cooling fan does not come into contact with the shroud when installed.
2) After installation, make sure there is no unusual noise or vibration when fan is rotated.
Coolant Temperature Sensor / Switch HVAC: Testing and Inspection
Thermo sensor is located on coolant outlet hose in engine room. Not engine overheated, if engine coolant temperature is over 115° C, electrical
current will not flow.
CHECKING
1. Immerse thermo sensor in engine coolant.
2. Using a stove, heating engine coolant, check that electrical current continues as shown.
below 115° C ................................... Continuity
over 115° C ................................. No continuity
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Sensor Testing
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
The engine coolant temperature sensor is installed in the engine coolant passage of the cylinder head. The ECM judges engine temperature by
the sensor output voltage and provides optimum fuel enrichment when the engine is cold.
CIRCUIT DIAGRAM
INSPECTION
1. Remove engine coolant temperature sensor from the intake manifold.
2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance.
3. If the resistance deviates greatly from the standard value, replace the sensor.
INSTALLATION
1. Apply sealant LOCTITE 962T or equivalent to threaded portion.
2. install engine coolant temperature sensor and tighten it to specified torque.
Torque: 20-40 Nm (14-29 ft.lbs.)
3. Securely connect the harness connector.
NOTE: If the fast idle speed is not enough or the engine gives off dark smoke during the engine warm-up operation, the engine coolant
temperature sensor might be the cause.
Using GST
Harness Inspection Procedure

Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Component Inspection
1. Heat the sensor by submerging it in hot engine coolant.

2. Check that the resistance is within the specified range.
Resistance:
At 20°C (68°F): 2.21 - 2.69 K ohms
At 80°C (176°F): 264 - 328 ohms
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
COMPONENTS
DISASSEMBLY
1. Drain the coolant down to sensor unit level or below.
2. Disconnect the battery ground cable and disconnect the engine harness. Remove the engine coolant temperature gauge unit and sensor.
REASSEMBLY
1. Apply sealant to the threaded portion and tighten to the specified torque.
Coolant temperature sender: Three bond No. 2310 or equivalent

Coolant temperature sensor: LOCTITE 962T or equivalent
Tightening torque:
Coolant temperature sender: 10 - 12 Nm ( 100 - 120 kgs.cm, 7 - 9 ft. lbs.)
Coolant temperature sensor: 20 - 40 Nm (200 - 400 kgs.cm, 14 - 29 ft. lbs.)
2. Connect the harness to the coolant temperature sender, sensor.

3. Connect the battery ground cable.
4. Refill with coolant.
Temperature Sensor (Gauge): Testing and Inspection
1. Heat the Engine coolant temperature gauge by submerging it in hot engine coolant.
2. Check that the resistance is within the specified range.
Resistance:
At 70°C (158°F): 90.5 - 117.5 ohms.
At 115°C (239°F): 21.3 - 36.3 ohms.
Temperature Gauge: Testing and Inspection
1. Disconnect the wiring connector from the engine coolant temperature sender in the engine compartment.
2. Turn the ignition switch ON, check that gauge needle indicates cool and turn the ignition switch OFF.
3. Ground to the harness side connector via the 12 V, 3.4 watt test bulb.
4. Turn the ignition switch ON.
5. Check to be sure that test bulb flashes and that the indicator moves to HOT.
If operation is as specified, replace the sender. Then recheck the system.
Radiator: Service and Repair
COMPONENTS
REMOVAL
1. Disconnect the ground cable from the battery terminal.

2. Disconnect the fan motor connector and the thermo sensor connector.
3. Loosen the radiator drain plug to drain the coolant.
4. Disconnect the upper and lower hoses and overflow tube after making marks on the radiator hose and the hose clamp.
5. For vehicles with automatic transaxles, disconnect the oil cooler hoses from the automatic transaxle.
CAUTION: Cover or plug the hose and nipple part of the radiator so that dust and other foreign materials do not enter after the hose has
been disconnected from the radiator.
6. Remove the radiator mounting bolt.

7. Remove the radiator and the fan motor.
8. Remove the radiator fan motor and condenser fan motor from the radiator.
INSPECTION
1. Check for foreign material between radiator fins.
2. Check the radiator fins for damage and straighten if necessary.
3. Check the radiator for corrosion, damage, rust or scale.
4. Check the radiator hoses for cracks, damage or deterioration.
5. Check the reserve tank for damage.
6. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration. (only A/T)
INSTALLATION
1. Fill the radiator and reservoir tank with clean coolant mixture.
2. Run the engine until the coolant has warmed up enough so that the thermostat valve opens and then stop the engine.
3. Remove the radiator cap and pour in the coolant until it is up to the filler neck of the radiator. Fill the reservoir tank to the upper level.
4. Check to be sure that there is no leakage from the radiator, hoses or connections.
Thermostat: Service and Repair
COMPONENTS
DISASSEMBLY
1. Drain the coolant down to thermostat level or below.
2. Remove the engine coolant outlet fitting and gasket.
3. Remove the thermostat.
INSPECTION
1. Heat the thermostat as shown in the illustration.

2. Check to see if the valve operates properly.
3. Determine the temperature at which the valve begins to open.
Valve opening temperature: 86.5 - 89.5°C ( 187.7 - 193.1°F)

Full opening temperature 100°C (212°F)
Thermo Sensor A (On Radiator)

Check for continuity with the thermo sensor in hot Engine coolant.
NOTE: Immerse thermo sensor in hot Engine coolant up to the mounting threads to check for continuity.
Operating temperature [NORMAL OPEN TYPE]:

OFF -> ON: 87 - 930°C (189 - 199°F)
ON -> OFF: 83°C or more (189 - 199°F)
Thermo Sensor B (On Radiator)
Operating temperature [NORMAL OPEN TYPE]:

OFF -> ON: 97 - 103°C (207 - 217°F)
ON -> OFF: 93°C or more (199°F)
Thermo Sensor (On Engine coolant outlet fitting)

Operating temperature [NORMAL CLOSE TYPE]:

OFF -> ON: 108°C or more (226°F)
ON -> OFF: 112 - 118°C (234 - 244°F)
REASSEMBLY
1. Check to ensure that the flange of the thermostat is correctly seated in the socket of the thermostat housing. If the thermostat is installed in the
wrong direction, the bottom of the thermostat will touch the rib inside the intake manifold, making it impossible to seat flange in position.
2. Install a new gasket and engine coolant outlet fitting bolt
Tightening torque:
Engine coolant outlet fitting bolt: 17 - 20 Nm (170 - 200 kgs.cm, 12 - 14 ft. lbs.)
3. Refill the coolant

Catalytic Converter: Testing and Inspection
INSPECTION
Inspect for damage, cracking or deterioration. Replace if faulty.
CAUTION: The catalytic converters require the use of unleaded gasoline only. Leaded gasoline will destroy the effectiveness of the
catalysts as an emission control device. Under normal operating conditions, the catalytic converters will not require maintenance. However, it
is important to keep the engine properly tuned. Engine misfiring may cause overheating of the catalysts. This may cause heat damage to the
converters or vehicle components. The situation can also occur during diagnostic testing if any spark plug cables are removed and the engine
is allowed to idle for a prolonged period of time.
Catalytic Converter: Service and Repair
COMPONENTS
DISASSEMBLY
Main Muffler
CAUTION: Before removing or inspecting the exhaust system, ensure that the exhaust system is cool.
1. Disconnect the main muffler from the center exhaust pipe.

2. Remove the rubber hangers and take out the main muffler.
Center Exhaust Pipe
1. Disconnect the center exhaust pipe from the main muffler and the catalytic converter.
2. Remove the rubber hangers and take out the center exhaust pipe.
Catalytic Converter
1. Disconnect the catalytic converter from the center exhaust pipe and front exhaust pipe.
Front Exhaust Pipe
1. Remove the front exhaust pipe-to-catalytic converter mounting bolts.

2. Remove the front exhaust pipe clamp bolt and remove the exhaust manifold-to-front exhaust pipe mounting nuts.
3. Remove the front exhaust pipe from the rubber hanger.
INSPECTION
1. Check the mufflers and pipes for corrosion and damage.
2. Check the rubber hanger and hangers for deterioration and cracks
INSTALLATION
1. Temporarily install, in the order specified, the front exhaust pipe, the catalytic converter assembly, the center exhaust pipe, and the main
muffler.
2. Install the rubber hangers so that they are identical (left and right) in length.
3. Tighten the parts securely, then confirm there is no interference with any body components.
Exhaust Manifold: Service and Repair
EXHAUST MANIFOLD
Check all parts for damage or cracking.
EXHAUST MANIFOLD GASKET

Check for flaking damage of the gasket.
Muffler: Service and Repair
COMPONENTS
DISASSEMBLY
Main Muffler
CAUTION: Before removing or inspecting the exhaust system, ensure that the exhaust system is cool.
1. Disconnect the main muffler from the center exhaust pipe.

2. Remove the rubber hangers and take out the main muffler.
Center Exhaust Pipe
1. Disconnect the center exhaust pipe from the main muffler and the catalytic converter.
Catalytic Converter
1. Disconnect the catalytic converter from the center exhaust pipe and front exhaust pipe.
Front Exhaust Pipe
1. Remove the front exhaust pipe-to-catalytic converter mounting bolts.

2. Remove the front exhaust pipe clamp bolt and remove the exhaust manifold-to-front exhaust pipe mounting nuts.
3. Remove the front exhaust pipe from the rubber hanger.
INSPECTION
1. Check the mufflers and pipes for corrosion and damage.
2. Check the rubber hanger and hangers for deterioration and cracks
INSTALLATION
1. Temporarily install, in the order specified, the front exhaust pipe, the catalytic converter assembly, the center exhaust pipe, and the main
muffler.
2. Install the rubber hangers so that they are identical (left and right) in length.
3. Tighten the parts securely, then confirm there is no interference with any body components.
Ignition System: Description and Operation
Ignition timing is controlled by the electric control ignition timing system. The ignition timing data for the engine operating conditions are
programmed in the memory of the engine control module (ECM).
*CKP : Crankshaft Position

*CMP : Camshaft Position
The engine conditions (speed, load, warm-up condition, etc.) are detected by the various sensors. Based upon these sensor signals and the ignition
timing data, signals to interrupt the primary current are sent to the power transistor. The ignition coil is activated, and timing is controlled at the
optimum point.
Ignition Timing Connector: Locations
IGNITION TIMING ADJUSTMENT TERMINAL

Camshaft Position Sensor: Testing and Inspection
CAMSHAFT POSITION SENSOR
The CMP sensor senses the camshaft position sensor on compression stroke of the No. 1 and No. 4 cylinders, converts it into a pulse signal,
and inputs it to the ECM. The ECM then computes the fuel injection sequence, etc. based on the input signal.
NOTE: If the camshaft position sensor does not operate correctly, correct sequential injection is not made so that the engine may stall or run
irregularly at idle or fail to accelerate normally
HARNESS INSPECTION
NOTE: If the CMP Sensor does not operate correctly, correct sequential injection is not made so that the engine may stall or run irregularly at
idle or fail to accelerate normally.
Camshaft Position Sensor: Service and Repair
1. Remove the battery ground cable.

2. Remove the camshaft position sensor mounting bolt.
3. Pull out the camshaft position sensor from cylinder head.
4. Check the camshaft position sensor.

5. After check, securely install the CMP sensor.
Tightening Torque: 8 Nm (80 kg.cm, 6 lb.ft) Min

Crankshaft Position Sensor: Testing and Inspection
CRANKSHAFT POSITION SENSOR
The crankshaft position sensor senses the crank angle (piston position) of each cylinder and converts it into a pulse signal. Based on the input
signal, the ECM computes the engine speed and controls the fuel injection timing and ignition timing.
NOTE:
1. If unexpected shocks are felt during driving or the engine stalls suddenly, shake the crankshaft position sensor harness. If this causes the
engine to stall, check for poor sensor connector contact.
2. If the tachometer reads 0 rpm when the engine is cranked, check for faulty crank angle sensor, broken timing belt or ignition system
problems.
3. If the engine can be run at idle even if the crank angle sensor reading is out of specification, check the following:
- Faulty engine coolant temperature sensor
- Faulty idle speed control motor Poorly adjusted reference idle speed
Using GST
HARNESS INSPECTION
Distributor: Service and Repair
Removal and Installation
COMPONENTS
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the two distributor cap retaining bolts and move the cap to one side.
3. Remove the distributor mounting nut and the distributor assembly.
INSTALLATION
1. Turn the crankshaft so that the No. 1 cylinder is at top dead center.
2. Align the distributor housing and gear mating marks.
3. Install the distributor in the engine while aligning the groove of the distributors installation flange with the center of the distributor
installation stud.
Distributor: Service and Repair
Disassembly and Reassembly
DISASSEMBLY
1. Lightly clamp the distributor in a vise equipped with soft jaws.
2. Remove the rotor installation screw and pull off the rotor from the rotor shaft.
3. Remove the rotor shaft mounting screw.
4. Remove the shaft bearing tightening screws.
5. Place the drive gear on a soft base (wooden block) so that the spring pin can be removed.
6. Remove the spring pin using removed punch.
REASSEMBLY
SHAFT
After coating the shaft with a small amount of engine oil, insert it into the housing.
CAUTION
Do not use solvent or similar products.
DRIVE GEAR
1. Mount the gear on the shaft, aligning it with the mating mark.
2. When aligning the mark on the gear and the housing, line up the pin holes with notch "A" on the end of the shaft as shown in the figure, then
drive in a new pin.
CAUTION: Drive in the pin so that the slit is at a right angle to the shaft.
Ignition Cable: Testing and Inspection
1. Disconnect, one at a time each of the spark plug cables while the engine is idling to check whether the engine's running performance changes
or not.
CAUTION: Wear rubber gloves while doing so.
2. If the engine performance does not change, check the resistance of the spark plug, and check the spark plug itself.
3. Check the cap and outer shell for cracks.
4. Measure the resistance.
NOTE: Resistance should not be higher than 10,000 Ohms per foot of cable. If resistance is higher, replace the cable.
Ignition Cable: Service and Repair
Improper arrangement of spark plug cables will induce voltage between the cables, causing misfiring and surging at acceleration in high-speed
operation.
Therefore, be careful to arrange the spark plug cables properly as shown in the illustration.
Ignition Coil: Testing and Inspection
Coil Testing
1. Measurement of the primary coil resistance.
2. Measure the resistance between connector terminals 3 and 2 (the coils at the No.1 and No.4 cylinder sides) of the ignition coil, and between
terminals 3 and 1 (the coils at the No.2 and No.3 cylinder sides).
Standard value : 0.77 - 0.95 Ohms
3. Measurement of the secondary coil resistance.
4. Measure the resistance between the high-voltage terminal for the No.1 and No.4 cylinders, and between the high-voltage terminals for the
No.2 and No.3 cylinders.
Standard value : 10.3 - 13.9 K Ohms
CAUTION: Be sure, when measuring the resistance of the secondary coil, to disconnect the connector of the ignition coil.
Ignition Coil: Testing and Inspection
Harness Inspection
HARNESS INSPECTION PROCEDURES IGNITION COIL
The ignition power transistor functions to control the ignition timing by controlling the ignition coil primary current by signals from the ECM.
CIRCUIT DIAGRAM
USING GST
Harness Inspection
Power Transistor: Testing and Inspection
1. Turn the ignition OFF.

2. Disconnect the ignition coil connector.
3. Connect a test lamp (12 V and 3 W or lower) between the battery positive terminal and No.1 (6) terminal of the power transistor.
CAUTION: The test lamp should be 12 V and 3 W or lower, Otherwise the power transistor may be burnt out.
4. Check the test lamp while cranking the engine. If the test lamp flasher, it is considered to be normal.
CAUTION: To prevent the battery from discharge, do not crank the engine more than 3 times for 10 seconds.
5. If not check the power transistor and replace it if defective.

Ignition Switch: Testing and Inspection
1. Separate the connector located under the steering column.
2. Inspect the switch continuity between the terminals.
3. If continuity is not as specified, replace the switch.
HINTS
If engine won't crank condition determine whether the condition exists with the transaxle range switch in the "PARK" or in the "NEUTRAL"
position.
If the "NO-CRANK" condition occurs in one shift lever position but not the other, a more probable cause is the transaxle range switch.
Ignition Switch: Service and Repair
1. Disconnect the negative battery terminal.
2. Remove the air bag module.
CAUTION: The SRS system is designed to retain enough power to deploy air bag for about 30 seconds even after battery has been
disconnected, so serious injury may result from unintended air bag deployment if service is done on the SRS system immediately after battery
cable is disconnected.
3. Loosen the tapping screws and lift up horn pad and remove it.
4. Remove the lock nut and the washer.
5. Pulling the dynamic damper forward, lift it up and remove it.
6. Install the special tool (09561-11001) and remove the steering wheel.
CAUTION: Do not hammer on the steering wheel to remove it.
7. Remove the steering column lower and upper shrouds.

8. Remove the lower cover.
9. Disconnect the connectors and remove the multifunction switch.

10. Remove the mounting bolts and separate ignition switch from steering column.
Spark Plug: Application and ID
NGK ............................................................................................................................................................................................................. BPR6ES-11
Champion ......................................................................................................................................................................................................... RN9YC4
Spark Plug: Testing and Inspection
1. Remove the spark plug and connect to the spark plug cable.
2. Ground the spark plug outer electrode, and crank the engine.
3. Check to be sure that there is an electrical discharge between the electrodes at this time.
Inspection and Cleaning
1. Disconnect the spark plug cable from the spark plug.
NOTE: Pull on the spark plug cable boot when removing the spark plug cable, not the cable, as it may be damaged.
2. Using spark plug wrench, remove all of the spark plugs from the cylinder head.
NOTE: Take care not to allow contaminants to enter through the spark plug holes.
3. Check spark plugs for the following:

1. Broken insulator
2. Worn electrode
3. Carbon deposits
4. Damaged or broken gasket
5. Condition of the porcelain insulator at the tip of the spark plug
4. Check the spark plug gap using a wire gap gauge, and adjust if necessary.
Standard value:
Spark plug gap .............................. 1.0-1.1 mm (0.039-0.043 in.)
5. Re-insert the spark plug and tighten to the specified torque. If it is overtorqued, damage to the threaded portion of cylinder head may result.
Tightening torque
Spark plug .......................... 20-30 Nm (204-306 kg.cm, 15-21 lb.ft)
Analyzing
Engine conditions can be analyzed by the tip deposits near the electrode.
Fuel Delivery and Air Induction: Description and Operation
MULTIPORT FUEL INJECTION (MFI) SYSTEM
The MFI system employs the signals from the heated oxygen sensor to activate and control the injector installed in the manifold for each
cylinder, precisely regulating the air/fuel mixture ratio and reducing emissions.
This allows the engine to produce exhaust gases of the proper composition to permit the use of a three-way catalyst. The three-way catalyst is
designed to convert the three pollutants (1) hydrocarbons (HC), (2) carbon monoxide (CO), and (3) oxides of nitrogen (NOx) into harmless
substances. The two operating modes in the MFI system are as follows:
1. Open Loop-air/fuel ratio is controlled by information programmed into the ECM during the manufacturing process.
2. Closed Loop-air/fuel ratio is varied by the ECM based on information supplied by the heated oxygen sensor.
Fuel Pressure: Testing and Inspection
FUEL PRESSURE TEST
- Disconnect the fuel pump harness connector under the rear seat.
3. Using the fuel pressure gauge adapter (09353-34000), install the fuel-pressure gauge to the fuel high pressure hose.
4. Connect the battery's negative (-) terminal.
5. Apply battery voltage to the fuel pump drive terminal, activate the fuel pump; then, with fuel pressure applied, check that there is no fuel
leakage from the pressure gauge or connection pan.
6. Start the engine and let it idle.
Disconnecting Fuel Pressure Regulator Vacuum Hose
7. Disconnect the vacuum hose from the pressure regulator and plug the hose end. Measure the fuel pressure at idle.
Fuel pressure 320-340 kPa (3.26-3.47 kg/sq.cm,46-49 psi)
8. Measure the fuel pressure when the vacuum hose is connected to the pressure regulator.
Fuel pressure approximately 270 kPa (2.75 kg/sq.cm, 39 psi)
9. If the results of the measurements made in steps (7) and

(8) are not within the standard value, use the table to determine the probable cause, and make the necessary repairs.
10. Stop the engine and check for a change in the fuel pressure gauge reading, which should hold for approximately 5 minutes. If the gauge
indication drops, observe the rate of drop. Determine the probable causes and repair them according to the table.
11. Reduce the fuel pressure in the fuel line.
12. Disconnect the high pressure hose and remove the fuel pressure gauge.
13. Connect the high pressure fuel hose to the fuel line to the specified torque.
Tightening torque 30-40 kPa (300-400 kg/sq.cm, 22-29 psi)
14. Check for fuel leaks.

- Apply battery voltage to the fuel pump drive terminal to operate the fuel pump.
- With pressure, check the fuel line for leaks.
Idle Speed: Adjustments
IDLE SPEED ADJUSTMENT
NOTE Before adjusting, check that the spark plugs, injectors, ISC motor, compression, etc. are normal. Clean the throttle body area.
Adjustment Conditions:
Engine coolant temperature is 80 to 95°C (176 to 205°F).
- Lights, electric cooling fan and all accessories are off.
- Transaxle is in neutral ["P" or "N" range for ATX vehicles].
- Steering wheel in straight forward position (vehicles with power steering).
Procedure
1. Loosen the accelerator cable.
2. Connect the GST to the data link connector on the lower crash pad.
3. If the GST is not used, connect a tachometer, and ground the data link connector.
4. Ground the ignition timing adjustment terminal.

5. Run the engine for more than 5 seconds at an engine speed of 2,000 to 3,000 rpm.
6. Run the engine at idle for 2 minutes.
7. Check that the engine rpm is within the standard value.
Basic idle speed 750 +/- 100 rpm
NOTE
1) The engine speed on a new vehicle driven less than 500Km (300 miles) may be 20 to 100 rpm lower than specification, but no adjustment
is necessary.
2) If the engine stalls or the engine speed is low after the vehicle has been driven a distance of 500 km (300 miles) or more, a deposit on the
throttle valve area is suspected.
8. If the basic idle speed is out of specification, adjust basic idle the speed.
NOTE: If the idle speed is higher than specified, even with the speed adjusting screw (SAS) fully closed, check whether the idle switch
(fixed SAS) moving mark exists or not. If it is found that the switch has moved, adjust the idle switch (fixed SAS) has been mis-adjusted.
9. Turn the ignition switch to the OFF position.

10. If the GST is not used, disconnect the data link connector.
11. Disconnect the lead wire from the ignition timing adjusting terminals.
12. Run the engine again and let it idle for about 10 minutes. Check that the engine is in normal idling condition.
Accelerator Pedal: Service and Repair
Left Hand Drive

1. Remove the accelerator arm bushing and inner cables.
2. Loosen the bolts of the accelerator arm bracket and remove.
Right Hand Drive

1. Remove the bushing and inner cable of the accelerator arm side.
2. Pull the left side of the accelerator pedal toward you, and then remove the accelerator pedal from the accelerator arm.
3. Loosen the bolts of the accelerator arm bracket and remove.
INSPECTION
1. Check the inner and outer cable for damage.
2. Check the cable for smooth movement.
3. Check the accelerator arm for deformation.
4. Check the return spring for deterioration.
5. Check the connection of the bushing to end metal fitting.
6. Check the accelerator proper operation.
Accelerator Cable, Pedal End Grease Point
LEFT HAND DRIVE INSTALLATION

1. When installing the return spring and accelerator arm, apply multi-purpose grease around each moving point of the accelerator arm.
2. Apply sealant to the bolt mounting hole, and tighten the accelerator arm bracket.
Accelerator arm bracket bolt torque: 8-12 Nm (6-7 ft.lbs.)
3. Securely install the resin bushing of the accelerator cable on the end of the accelerator arm.
RIGHT HAND DRIVE INSTALLATION

1. When installing the return spring and accelerator arm, apply multi-purpose grease around each moving point of the accelerator arm.
2. Apply sealant to the bolt mounting hole, and tighten the accelerator arm bracket.
Accelerator arm bracket bolt torque: 8-12 Nm (6-7 ft.lbs.)
3. Securely install the resin bushing of the accelerator cable on the end of the accelerator arm.
4. Apply multipurpose grease around the cable end.
Air Cleaner Housing: Service and Repair
COMPONENTS
DISASSEMBLY
1. Remove the air intake hose and air duct connected to the air cleaner, and the resonator.
2. Remove the three bolts attaching the air cleaner mounting brackets.
3. Detach the air cleaner.
4. Remove the volume air flow sensor from the air cleaner case.
CAUTION: Do not pull on the volume air flow sensor harness, because the grommet is attached to the air cleaner case.
INSPECTION
1. Check the air cleaner body, cover, or packing for distortion, corrosion or damage.
2. Check the air duct for damage.
3. Check the air cleaner element for restriction, contamination or damage. If the element is slightly restricted, remove the dust and other
contaminants by blowing air from the inside through the element.
4. Check the air cleaner housing for restrictions, contamination or damage.
5. Check the resonator for damage.
REASSEMBLY
Install the air cleaner in the reverse order of removal.
Volume Air Flow Sensor: Testing and Inspection
Circuit Testing
VOLUME AIR FLOW (VAF) SENSOR
The VAF Sensor measures the intake air volume. It makes use of a Karman vortex to detect the air flow rate and sends it to the ECM as the
intake air volume signal. The ECM uses this intake air volume signal to decide the basic fuel injection duration.
NOTE:
1. If the engine stalls occasionally, crank the engine and shake the VAF Sensor harness. If the engine stalls, check for the poor contact of the
VAF Sensor connector.
2. If the VAF Sensor output frequency is other than 0 when the ignition switch is turned on (do not start the engine), check for the faulty VAF
Sensor of ECM.
3. If the engine can be idle even if the VAF Sensor output frequency is out of specification, check for the following conditions.
- Disturbed air flow in the VAF Sensor. Disconnected air duct, clogged air cleaner filter.
- Poor combustion in the cylinder. Faulty ignition plug, ignition coil, injector incorrect compression.
- Air leaks in the intake manifold.
- Loose EGR valve seat.
Using GST
NOTE: When the vehicle is new [within initial operation of about 500 km (300 miles)], the volume air flow sensor output frequency may be
about 10% higher.
HARNESS INSPECTION PROCEDURES

Volume Air Flow Sensor: Testing and Inspection
Sensor Testing
DTC - P0100
Detection Condition
The Volume Air Flow (VAF) sensor is located in the air cleaner. The sensor measures the volume of air passing though the air intake and
generates a pulsed signal. The Engine Control Module (ECM) counts the pulses generated by the sensor and uses the signal to set fuel
injector base pulse width.
Part 1 of 2
Part 2 of 2
Fuel Filter: Service and Repair
CAUTION: Be sure to reduce the fuel pressure before disconnecting the fuel feed pipe, otherwise fuel will spill out. Cover the pipe connection
with shop towel to prevent fuel from splashing (caused by residual pressure in the fuel line).
1. Raise the vehicle and remove the two fitting nuts while holding the fuel filter nut securely.
2. Remove the fuel filter mounting bolts, and then remove the fuel filter from the bracket.
Fuel filter fitting nut torque: 25-35 Nm (18-25 ft.lbs.)

Fuel Injector: Testing and Inspection
FUEL INJECTOR
The injectors inject fuel according to a signal coming from the ECM. The amount of fuel injected by the injectors is determined by the time
during which the solenoid valve is energized.
NOTE:
1. If the engine is hard to start when hot, check for fuel pressure and injector leaks.
2. If the injector does not operate when the engine is cranked, check for the following:
- Faulty power supply circuit to the ECM; faulty ground circuit
- Faulty control relay
- Faulty Crankshaft Position (CKP) sensor, camshaft position (CMP) sensor.
3. If any cylinder's idle state remains unchanged when the fuel injection of each injector is cut one after another during idling, check the
following:
- Injector and harness
- Ignition plug and high tension cable
- Compression pressure
4. If the injection system is OK, but the injector drive time is out of specification, check for the following:
- Injector and harness
- Poor combustion in the cylinder (faulty ignition plug, ignition coil, compression pressure, etc.)
- Loose EGR valve seating
Using GST
NOTE
(1) The injector drive time refers to when the supply voltage is 11V and the cranking speed is less than 250 rpm.
(2) When engine coolant temperature is lower than 0°C (32° F), the ECM fires all four cylinders simultaneously.
(3) When the vehicle is new (within initial operation of about 500 km [300 miles]), the injector drive time may be about 10% longer.

Actuator Inspection
Operational Check
Using a GST, check as described below.
- Cut off the fuel injectors in sequence.
- Check the operation time of the injectors.
Operational Sound Check

1. Using a stethoscope, check the injectors for a clicking sound at idle. Check that the sound is produced at shorter intervals as the engine speed
increases.
NOTE: Ensure that the sound from an adjacent injector is not

being transmiffed along the delivery pipe to an inoperative injector.
2. If a stethoscope is not available, check the injector operation with your finger. If no vibrations are felt, check the wiring connector, injector,
or injection signal from ECM.
Resistance Measurement Between Terminals
3. Disconnect the connector at the injector.
4. Measure the resistance between terminals.
Standard value 13-16 ohms @ 20°C (68°F)
5. Connect the connector to the injector.

Fuel Injector: Service and Repair
REMOVAL
1. Release residual pressure from the fuel line to prevent fuel spilling.
CAUTION: Cover the hose connection with rags to prevent splashing of fuel that could be caused by residual pressure in the fuel line.
2. Remove the delivery pipe with the fuel injector and pressure regulator.
INSTALLATION
1. Install a new grommet and O-ring to the injector.
2. Apply a coating of solvent, spindle oil or gasoline to the injector O-ring.
3. While turning the injector to the left and right, install it on to the delivery pipe.
4. Be sure the injector turns smoothly.
NOTE: If injector does not turn smoothly, the O-ring may be lammed. Remove the injector and re-insert it into the delivery pipe and
re-check.
Fuel Pump: Testing and Inspection
Fuel Pump Operational Check
FUEL PUMP OPERATION CHECK

2. Apply battery voltage to the fuel pump drive connector to check that the pump operates.
NOTE: The fuel pump is in-tank type and its operating sound is hard to hear without removing the fuel tank cap.
3. Pinch the hose to check that fuel pressure is felt.

Harness Inspection
FUEL PUMP (FP)
TESTING USING GST

HARNESS INSPECTION
Fuel Pump Testing
FUEL PRESSURE TEST
- Disconnect the fuel pump harness connector under the rear seat.
3. Using the fuel pressure gauge adapter (09353-34000), install the fuel-pressure gauge to the fuel high pressure hose.
4. Connect the battery's negative (-) terminal.
5. Apply battery voltage to the fuel pump drive terminal, activate the fuel pump; then, with fuel pressure applied, check that there is no fuel
leakage from the pressure gauge or connection pan.
6. Start the engine and let it idle.
Disconnecting Fuel Pressure Regulator Vacuum Hose
7. Disconnect the vacuum hose from the pressure regulator and plug the hose end. Measure the fuel pressure at idle.
Fuel pressure 320-340 kPa (3.26-3.47 kg/sq.cm,46-49 psi)
8. Measure the fuel pressure when the vacuum hose is connected to the pressure regulator.
Fuel pressure approximately 270 kPa (2.75 kg/sq.cm, 39 psi)
9. If the results of the measurements made in steps (7) and

(8) are not within the standard value, use the table to determine the probable cause, and make the necessary repairs.
10. Stop the engine and check for a change in the fuel pressure gauge reading, which should hold for approximately 5 minutes. If the gauge
indication drops, observe the rate of drop. Determine the probable causes and repair them according to the table.
11. Reduce the fuel pressure in the fuel line.
12. Disconnect the high pressure hose and remove the fuel pressure gauge.
13. Connect the high pressure fuel hose to the fuel line to the specified torque.
Tightening torque 30-40 kPa (300-400 kg/sq.cm, 22-29 psi)
14. Check for fuel leaks.

- Apply battery voltage to the fuel pump drive terminal to operate the fuel pump.
- With pressure, check the fuel line for leaks.
Fuel Supply Line: Testing and Inspection
INSPECTION
1. Check the hoses and pipes for cracking, bending, deformation or restrictions.
2. Check the EVAP Canister for restrictions.
3. Check the fuel filter for restrictions and damage.
Fuel Supply Line: Service and Repair
FUEL LINE AND VAPOR LINE COMPONENTS REMOVAL

1. Raise the vehicle and remove the two fitting nuts while holding the fuel filter nut securely.
CAUTION:
(1) Reduce the fuel pressure before disconnecting the fuel line and hose, or fuel will spill out.
(2) Cover the pipe connection with a shop towel to prevent splashing of fuel that could be caused by residual pressure In the fuel line.
2. Remove the fuel filter mounting bolts, then remove the fuel filter from the bracket.
3. Remove the fuel return hose and line.
4. Remove the fuel vapor hose and line
INSPECTION
1. Check the hoses and pipes for cracking, bending, deformation or restrictions.
2. Check the EVAP Canister for restrictions.
3. Check the fuel filter for restrictions and damage.
INSTALLATION
1. Install the fuel vapor hose and return hoses.
- If the fuel line has a stepped section, connect the fuel hose to the line securely, as shown in the illustration.
- If the fuel line does not have a stepped section, connect the fuel hose to the line securely.
2. Install the fuel filter, and tighten the fuel filter bracket.
3. Tighten the two fitting nuts while holding the fuel filter nuts.
Fuel filter fitting nuts torque: 30-40 Nm (22.1-29.5 ft.lbs.)
4. Install the clips and make sure that they do not interfere with other components.
Fuel Tank: Service and Repair
REMOVAL
1. To reduce the internal pressure of the fuel main pipes and hose, first start the engine and then disconnect the electrical fuel pump connector in
the rear seat side.
CAUTION: Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose otherwise fuel will spill out.
2. Disconnect the battery cable from the negative terminal of the battery.
3. Remove the fuel tank cap.
4. Remove the drain plug and drain the fuel.
5. Disconnect the return hose and vapor hose.
6. Disconnect the fuel sender connector.
7. Disconnect the high pressure hose from the fuel tank.

8. Loosen the two self-locking nuts, that hold tank in the position and remove the two tank bands.
9. Detach the fuel filler hose and leveling hose.

10. Remove the fuel vapor hose and the fuel tank.
INSPECTION
1. Check the hoses and the pipes for cracks or damage.
2. Check the fuel tank cap for proper operation.
3. Check the fuel tank for deformation, corrosion or cracking.
4. Check the fuel tank inside for dirt or foreign material.
5. Check the in-tank fuel filter for damage or restriction.
6. Test the two-way valve for proper operation. Using a vacuum hand pump.
Fuel Hose Connection Specifications
INSTALLATION
1. Connect the leveling hose to the tank and approximately 40 mm (1.6 in.) at the filler neck.
2. When connecting the filler hose, connect the end with the shorter straight pipe to the tank side.
3. Confirm that the pad is fully bonded to the fuel tank. Install the fuel tank by tightening the self-locking nuts to the tank bands until the rear
end of the tank band contacts the body.
4. Connect the vapor hose and return hose. Attach the fuel hose to the line as shown in the illustration.
5. To connect the high pressure hose to the fuel pump, temporarily tighten the flare nut by hand, and then tighten it to the specified torque. Be
careful that the fuel hose does not twist.
High pressure hose flare nut torque: 30-40 Nm (22-29 ft.lbs.)
NOTE: When tightening the flare nut, be careful not to bend or twist the line to prevent damage to the fuel pump connection.
6. Connect the electrical fuel pump and fuel sender connector.
7. Tighten the drain plug to the specified torque.
Drain plug torque: 15-25 Nm (11-18 ft.lbs.)

Fuel Tank Unit: Service and Repair
FUEL SENDER REPLACEMENT

1. Remove the fuel tank cap to lower the fuel tank's internal pressure.
2. Lift up the vehicle and remove the fuel tank.
3. Remove the fuel sender installation screws, then remove the fuel sender from the fuel tank.
Idle Speed Control Motor: Testing and Inspection
IDLE SPEED CONTROL (ISC) ACTUATOR

The intake air volume at idle is controlled by opening or closing the motor valve provided in the air path that bypasses the throttle valve.
NOTE:
1. If the stepper motor step increases to 100-120 steps or decreases to 0 steps, check for faulty stepper motor or open circuit in the harness.
2. If the idle speed control motor is normal but the stepper motor steps are out of specification, check the following:
- Poorly adjusted reference idle speed
- Deposit on the throttle valve
- Air leaking into the intake manifold through gasket gap
- Loose EGR valve seat
- Poor combustion in the cylinder (faulty ignition plug, ignition coil , injector, low compression pressure, etc.)
Using GST
NOTE: When the vehicle is new (about 500 km [at 20°C (68°F)300 miles]), the stepper motor steps may be about 30 steps more than standard.

Actuator Inspection
Operation Sound Check

1. Check for the sound of the stepper motor after the ignition is switch ON (but without starting the motor).
2. If the operation sound cannot be heard, check the stepper motor's circuit.
3. If the circuit is normal, the problem may be the stepper motor or the ECM
Resistance Measurement between terminals Measure the resistance between the respective terminals
Standard value
Terminals 2-3 or 1 28-33 Ohms @ 20°C (68°F)
Terminals 5-4 or 6 28-33 Ohms @ 20°C (68°F)
Operation Check
Apply voltage as follows and check whether or not stepper motor movement occurs.
1. Connect the power supply (approx. 6V) terminal (+) to terminals 2 and 5 of the connector.
2. Connect the power supply (-) terminal to terminals 3 and 4
6. Connect the power supply (-) terminal to terminals 1 and 4.
- Repeat the tests in sequence from (6) to (1) if vibration is detected, the stepper motor can be considered to be normal
Idle Speed Control Motor: Service and Repair
THROTTLE BODY COMPONENTS REMOVAL
CAUTION:
(1) The throttle valve must not be removed.
(2) When loosening a firmly tightened phillips screw, use the proper phillips screwdriver for the screw.
Main Relay (Computer/Fuel System): Testing and Inspection
MFI CONTROL RELAY
When the ignition switch is turned on, battery voltage is applied from the ignition switch to the ECM, turning ON the ignition power
transistor and energizing the MFI control relay coil. This turns ON the MFI control relay switch, and supplies power from the battery to the
ECM through the MFI control relay switch.
CIRCUIT DIAGRAM
USING GST

MFI Control Relay Inspection
NOTE: When applying battery voltage directly, make sure it is applied to the correct terminal. Otherwise, the relay could be damaged.
1. Connect a 12V power supply (+) terminal to terminal 6 of the MFI control relay and measure the voltages at terminal 1 when the (-) terminal
is connected to and disconnected from the terminal 8.
2. Connect a 12V power supply (-) terminal to terminal 10 of the MFI control relay and check the continuity between terminals 3 and 4 when
the (+) terminal is connected to and disconnected from the terminal 7.
3. Connect a 12V power supply (+) terminal to terminal 3 of the MFI control relay. Measure the voltages at terminal 4 when the (-) terminal is
connected to and disconnected from the terminal 9.
4. If one of the above is improper, replace the MFI control relay.
Throttle Position Sensor: Testing and Inspection
Sensor/Harness Testing
Throttle Position Sensor
The TP Sensor is a rotating type variable resistor that rotates with the throttle body throttle shaft to sense the throttle valve angle. As the
throttle shaft rotates, the output voltage of the TP Sensor changes. The ECM detects the throttle valve opening based on voltage change.
NOTE: The TP Sensor signal is important in the control of the automatic transaxle. Shift shock and other trouble will occur if the sensor is
faulty.
Using GST

INSPECTION
1. Disconnect the throttle position sensor connector.
2. Measure resistance between terminal 1 (sensor ground) and terminal 4 (sensor power).
Standard value 3.5 - 6.5 k ohms
3. Connect a pointer type ohmmeter between terminal 1 (sensor ground) and terminal 3 (sensor output).
4. Operate the throttle valve slowly from the idle position to the full open position and check that the resistance changes smoothly in proportion
to the throttle valve opening angle.
5. If the resistance is out of specification, or fails to change smoothly, replace the throttle position sensor.
TP Sensor torque: 1.5 - 2.5 Nm (1.1 - 1.8 ft.lbs.)
6. Disconnected the idle position switch connector

7. Check the continuity between terminal 1 and sensor ground
Throttle Position Sensor: Testing and Inspection
Transaxle Related Testing
Transaxle KM175
THROTTLE POSITION SENSOR INSPECTION
Transaxle F4A33
3 - THROTTLE POSITION SENSOR

Throttle Position Sensor: Adjustments
THROTTLE POSITION SENSOR (TP SENSOR) ADJUSTMENT
1. Connect a Generic Scan Tool (GST) to the data link connector.
2. If a Generic Scan Tool is not used, connect a digital type voltmeter between terminals 1 and 3.
3. Turn the ignition switch to the ON position (do not start engine) and check that the TP Sensor output voltage is as specified. If a GST is used,
press code and read the voltage.
Standard value 400-1000 mV
4. If it is out of specification, loosen TP Sensor mounting screws and adjust by turning the TP Sensor.
NOTE: Turning the TP Sensor clockwise increases the output voltage. Tighten the screws securely after adjustment.

Throttle Position Sensor: Service and Repair
CAUTION:
Closed Throttle Position Switch: Adjustments
THROTTLE POSITION SENSOR (TP SENSOR) ADJUSTMENT
1. Connect a Generic Scan Tool (GST) to the data link connector.
2. If a Generic Scan Tool is not used, connect a digital type voltmeter between terminals 1 and 3.
3. Turn the ignition switch to the ON position (do not start engine) and check that the TP Sensor output voltage is as specified. If a GST is used,
press code and read the voltage.
Standard value 400-1000 mV
4. If it is out of specification, loosen TP Sensor mounting screws and adjust by turning the TP Sensor.
NOTE: Turning the TP Sensor clockwise increases the output voltage. Tighten the screws securely after adjustment.

Closed Throttle Position Switch: Service and Repair
CAUTION:
Throttle Body: Service and Repair
Throttle Body Cleaning
CAUTION:
1. The following components must not be cleaned by immersion in cleaning solvents.
- Throttle position sensor
- ISC motor assembly
- Idle position switch
2. The insulation of these components will be damaged if they are immersed in cleaning solvent. Instead, clean them with a piece of cloth.
THROTTLE BODY CLEANING

1. Warm up the engine, then stop it.
2. Remove the intake air hose from the throttle body.
3. Plug the bypass passage inlet of the throttle body.
NOTE: Make sure the solvent does not enter the by-pass passage.
4. Spray cleaning solvent onto the valve through the throttle body intake port and let it soak for about 5 minutes.
5. Start the engine, race it several times and allow the engine to idle for 1 minute.
6. Repeat Steps 4 and 5.
7. Unplug the bypass passage inlet.
8. Attach the intake air hose.
9. Disconnect the battery ground cable for more than 10 seconds.

10. Adjust the idle speed if out of specifications.
Computers and Control Systems: Description and Operation
MULTIPORT FUEL INJECTION GENERAL INFORMATION
The Multiport Fuel Injection System consists of sensors which detect the engine conditions, the ENGINE CONTROL MODULE (ECM)
which controls the system based on signals from these sensors, and actuators which operate under the control of the ECM. The ECM carries
out activities such as fuel injection control, idle air control and ignition timing control. In addition, the ECM is equipped with several
diagnostic test modes which simplify troubleshooting when a problem develops.
FUEL INJECTION CONTROL

The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the
continually-changing engine operation conditions. A single injector is mounted at the intake port of each cylinder. Fuel is sent under pressure
from the fuel tank by the fuel pump. with the pressure being regulated by the fuel pressure regulator. The fuel thus regulated is distributed to
each of the injectors. Fuel injection is normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is
1-3-4-2. This is called multiport. The ECM provides a richer air/fuel mixture by carrying out "open-loop" control when the engine is cold or
operating under high load conditions in order to maintain engine performance. In addition, when the engine is warm or operating under
normal conditions, the ECM controls the air/fuel mixture by using the heated oxygen sensor signal to carry out "closed-loop" control in order
to obtain the theoretical air/fuel mixture ratio that provides the maximum cleaning performance from the three way catalyst.
IDLE SPEED CONTROL

The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in
idling conditions and engine load during idling. The ECM drives the idle speed control (ISC) motor to keep the engine running at the pre-set
idle target speed in accordance with the engine coolant temperature and air conditioning load. In addition, when the air conditioning switch is
turned off and on while the engine is idling, the ISC motor operates to adjust the throttle valve bypass air amount in accordance with the
engine load conditions in order to avoid fluctuations in the engine speed.
IGNITION TIMING CONTROL

The ignition power transistor located in the ignition primary circuit turns ON and OFF to control the primary current flow to the ignition coil.
This controls the ignition timing in order to provide the optimum ignition timing with respect to the engine operating conditions. The ignition
timing is determined by the ECM from the engine speed, intake air volume, engine coolant temperature and atmospheric pressure.
OTHER CONTROL FUNCTIONS

1. Fuel Pump Control. : Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running.
2. A/C Compressor Clutch Relay Control. :Turns the compressor clutch of the A/C ON and OFF.
3. Fan Relay Control. The radiator fan and condenser fan speeds are controlled in response to the engine coolant temperature and vehicle speed.
4. Evaporative Emission Purge Control.
5. EGR Control.
Engine Control Module: Testing and Inspection
ENGINE CONTROL MODULE (ECM)
The Engine Control Module (ECM) Power Ground grounds the ECM.
NOTE: It the ground wire of the ECM is not connected securely to ground, the unit will not operate correctly.
HARNESS INSPECTION
A/C Signal: Testing and Inspection
AIR CONDITIONING SWITCH AND RELAY
The air conditioning switch applies the battery voltage to the ECM when the air conditioner is turned on. When the air conditioning ON
signal is input, the ECM drives the SC motor and turns ON the power transistor. And then the air conditioning power relay coil is energized
to turn on the relay switch, which activates the air compressor magnetic clutch.
CIRCUIT DIAGRAM
NOTE: If the air compressor magnetic clutch is not activated when the air conditioing switch is turned on during idling, faulty air conditioning
control system is suspected.
Using GST
Harness Inspection
Intake Air Temperature Sensor: Testing and Inspection
(IAT) INTAKE AIR TEMPERATURE SENSOR
The intake air temperature sensor, located on the VAF Sensor as shown in the illustration, is a resistor-based sensor for detecting the intake
air temperature.
Based on the intake air temperature information from the sensor, the ECM provides necessary fuel injection control.
NOTE: The intake air temperature sensor senses the intake air temperature in the air cleaner to indicate a temperature different from outside
temperature.
Using GST
1. Disconnect the volume air flow sensor connectors.

2. Measure resistance between terminals 4 and 6.
3. Measure resistance while heating the sensor with a hair drier.

4. If the value deviates from the standard value or the resistance remains unchanged, replace the volume air flow sensor assembly.
HARNESS INSPECTION PROCEDURE

Barometric Pressure Sensor: Testing and Inspection
BAROMETRIC PRESSURE SENSOR (BPS)
The barometric pressure sensor installed on the VAF Sensor senses the barometric pressure and converts it into a voltage which is sent to the
ECM.
The ECM uses this signal to compute the altitude at which the vehicle is operating and corrects the air-fuel ratio and the ignition timing, thus
improving driveability at high altitude.
CIRCUIT DIAGRAM
NOTE:
1. If the barometric pressure sensor is faulty, the vehicle will experience poor driveability.
2. If the pressure of the barometric pressure sensor drops greatly during high speed driving, check the air cleaner for clogging.
Using GST
HARNESS INSPECTION
Cranking Signal: Testing and Inspection
ATX
IGNITION SWITCH - ST AND TRANSAXLE RANGE(TR) SWITCH [A/T]
- When the ignition switch is set to the ST position, battery voltage is applied through the ignition switch and transaxle range switch to the
ECM.
- If the selector lever is not in the P or N position, battery voltage will not reach the ECM.
- Based on this signal, the ECM determines the automatic transaxle load and drives the ISC motor to maintain optimum idle speed.
CIRCUIT DIAGRAM
NOTE: If the TR switch harness check is normal but the TR switch output is abnormal, check for the control cable adjustment
Using GST
Harness Inspection
Cranking Signal: Testing and Inspection
MTX
IGNITION SWITCH - ST [M/T]
The ignition switch-ST inputs a high signal to the ECM while the engine is cranking. The ECM provides fuel injection control, etc. at engine
start-up based on this signal.
CIRCUIT DIAGRAM
USING GST
Harness Inspection
Fuel Tank Pressure Sensor: Testing and Inspection
DTC - P0450
The Fuel Tank Pressure sensor is used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is
an abnormality in the evaporative emission control system based on the vapor pressure sensor signal.
DTC PO45O is recorded by the ECM when the vapor pressure sensor malfunction.
TROUBLESHOOTING Part 1 of 2
Part 2 of 2
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR LIGHT (MIL)

An On Board Diagnostic lamp comes on to notify the driver that there is any problem on the vehicle.
However MIL will go off automatically after 3 subsequent sequential driving cycles not redetected same malfunction.
Immediately after the ignition switch is turn on, the malfunction indicator light is lit for 5 seconds to indicate that the malfunction indicator
light operates normally.
Following Items will be Indicated by the MIL
- Catalyst
- Fuel system
- Volume air flow sensor (VAF sensor)
- Intake Air Temperature Sensor (IAT sensor)
- Engine Coolant Temperature Sensor (ECT sensor)
- Throttle Position Sensor (TPS)
- Upstream Oxygen Sensor
- Downstream Oxygen Sensor Heater
- Downstream Oxygen Sensor
- Upstream Oxygen Sensor Heater
- Injector
- Misfire
- Crankshaft Position Sensor (CKP sensor)
- Camshaft Position Sensor (CMP sensor)
- Evaporative Emission Control System
- Vehicle Speed Sensor (VSS)
- Idle Speed Control
- ECM
- Manifold Differential Pressure (MDP) Sensor (Except 2.0L engine in *CAL)
- Idle Switch
- EGR System (Except 2.0L engine in *CAL)
Barometric Pressure Sensor (BP Sensor)
*CAL : California area.
Manifold Differential Pressure Sensor: Testing and Inspection
Sensor Testing
MANIFOLD DIFFERENTIAL PRESSURE SENSOR

This is the pressure sensor that converts the pressure value into an electric signal and gives the signal to ECM. If the differential pressure is
over -11 Hg. (in case of manual transmission ), -26 Hg. (in case of auto transmission ),it is expected for the MDP sensor to operate. In that
case, if EGR valve doesn't operate, there is a problem with the EGR valve.
The value of MDP (manifold differential pressure sensor) correlates with pressure.
INSPECTION
1. At idle, check the voltage using voltameter.
2. Pay attention to correct position of pin connected.
3. Check that the value is within the standard.
Standard value @ idle 2.0 ± 0.3 v
CAUTION: Do not drop the MDP sensor. If dropped, don't reuse it.
Manifold Differential Pressure Sensor: Testing and Inspection
Circuit Testing
MANIFOLD DIFFERENTIAL PRESSURE (MDP) SENSOR
The MDP sensor converts the pressure of intake manifold caused by exhaust gas to voltage and input it to the ECM. The ECM judges the
condition of the EGR by this signal EGR incoming. If there is abnormal condition, the engine warning light is turned on to notify the driver.
CIRCUIT DIAGRAM
HARNESS INSPECTION
HO2S: Testing and Inspection
HEATED OXYGEN SENSOR (HO2S) - II
The heated oxygen sensor senses the oxygen concentration in exhaust gas, converts it into a voltage, which is sent to the ECM. The oxygen
sensor outputs about 1V when the air fuel ratio is richer than the theoretical ratio, and outputs about 0V when the ratio is leaner (higher
oxygen concentration in exhaust gas.). The ECM controls the fuel injection ratio based on this signal so that the air fuel ratio is maintained at
the theoretical ratio. The oxygen sensor has a heater element which ensures the sensor performance during all driving conditions.
NOTE:
1. If the HO2S is defective, abnormally high emissions may occur.
2. If the HO2S check results were normal, but the sensor output voltage is out of specification, check for the following items (related to air fuel
ratio control system):
- Faulty injector
- Air leaks in the intake manifold.
- Faulty volume air flow sensor, intake air temperature sensor, barometric pressure sensor, engine coolant temperature sensor.
Using GST
NOTE Before checking, warm up the engine until the engine coolant temperature reaches 80 to 95°C (176 to 205°F). Use an accurate digital
voltmeter.
1. Disconnect the oxygen sensor connector, and measure the resistance between terminal 3 and terminal 4.
Standard value
2. Replace the oxygen sensor if there is malfunction.

3. Apply battery voltage directly between terminal 3 and terminal 4.
NOTE: Take care when applying the voltage. Damage will result if the terminals are incorrect or are short circuited.
4. Connect a digital-type voltmeter between terminal 1 and terminal 2.
5. While repeatedly racing the engine, measure the oxygen sensor output voltage.
6. If there is a problem, there may be an oxygen sensor malfunction.
Heated oxygen sensor torque: 40-50 Nm (29-36 ft.lbs.)

Power Steering Pressure Switch: Testing and Inspection
POWER STEERING PRESSURE (PSP) SWITCH

The power steering oil pressure switch senses the power steering load into low/high voltage and inputs it to ECM, which then controls the
idle speed control motor based on this signal.
CIRCUIT DIAGRAM
HARNESS INSPECTION PROCEDURE

Transmission Position Switch/Sensor: Testing and Inspection
Harness Inspection
MTX
IGNITION SWITCH - ST [M/T]
The ignition switch-ST inputs a high signal to the ECM while the engine is cranking. The ECM provides fuel injection control, etc. at engine
start-up based on this signal.
CIRCUIT DIAGRAM
USING GST
Harness Inspection
ATX
IGNITION SWITCH - ST AND TRANSAXLE RANGE(TR) SWITCH [A/T]
- When the ignition switch is set to the ST position, battery voltage is applied through the ignition switch and transaxle range switch to the
ECM.
- If the selector lever is not in the P or N position, battery voltage will not reach the ECM.
- Based on this signal, the ECM determines the automatic transaxle load and drives the ISC motor to maintain optimum idle speed.
CIRCUIT DIAGRAM
NOTE: If the TR switch harness check is normal but the TR switch output is abnormal, check for the control cable adjustment
Using GST
Harness Inspection
P/N Position Switch
1. Disconnect the connector.
2. Check that there Os continuity between connector terminals 10 and 11 when the shift lever is moved to the "N" range.
Transaxle F4A33
11 - TRANSAXLE RANGE SWITCH

Transaxle KM175
TRANSAXLE RANGE SWITCH INSPECTION

Transmission Position Switch/Sensor: Adjustments
TRANSAXLE RANGE SWITCH ADJUSTMENT

1. Place the selector lever in the "N" (Neutral) position.
2. Loosen the manual control lever lock nut to separate the cable and lever.
3. Place the manual control lever in the "N" (Neutral) position.
4. Turn the transaxle range switch body until the 12 mm (47 in.) wide end of the manual control lever aligns with the switch body flange [12
mm (0.472 in.) wide portion].
5. Tighten the attaching bolts (2 pcs.) to the specified torque.
Transaxle Range Switch Attaching Bolt torque: 10-12 Nm (7-9 ft.lbs.)
NOTE: When setting up the switch body, be careful O-ring not to drop from the switch body. Tighten the attaching bolts carefully.
6. Make sure that the selector lever is in the "N" (Neutral) position.
7. Adjust the flange nut so that there is no slack in the control cable and make sure that the selector lever operates smoothly.
8. Run the vehicle and confirm that the transaxle is set in each range when the selector lever is shifted to each position.
Vehicle Speed Sensor: Testing and Inspection
VEHICLE SPEED SENSOR (VSS)

The vehicle speed sensor is a hall 10 type. The speed sensor converts the transaxle gear revolutions into pulse signals, which are sent to the
ECM.
CIRCUIT DIAGRAM
HARNESS INSPECTION
INSPECTION
1. Disconnect the speed sensor connector and remove the speed sensor.
2. Connect the positive (+) lead from battery to terminal 2 and the negative (-) lead to terminal 1.
3. Connect the positive (+) lead from tester to terminal 1 and negative (-) lead to terminal 3.
4. Turn the speed meter shaft using a flat driver.
5. Check for a voltage change from about 0V to 11 V or more between terminals 1 and 3.
6. The voltage change should be 4 times per each revolution of the shaft.
NOTE: If there is an open or short circuit in the vehicle speed sensor signal circuit, the engine may stall when decelerating to stop the
vehicle.
Vehicle: Specifications
ABS Light
Power Consumption ......................................................................................................................................................................................... 1.2 Watts
Service Reminder Indicator Fuse ...................................................................................................................................................................... 10 Amps
Standard Optional
Type NX100-S6MF MF 68 AH
Cold Cranking Amps 433 A 540 A
Reserve Capacity 80 minutes 122 minutes
Coil Current
Coil Current
Current 0.45 Amp Or Less @ 12 V
Generator Type Battery Voltage Sensing
Rated Output 12 Volts / 90 Amps
Voltage Regulator Type Electronic built-in type
Tempeture Compensated -10 +/- 3 mV / deg. C
Regulating Voltage 14.4 +/- 0.3 Volts
Generator Type Battery Voltage Sensing
Rated Output 12 Volts / 90 Amps
Voltage Regulator Type Electronic built-in type
Tempeture Compensated -10 +/- 3 mV / deg. C
Regulating Voltage 14.4 +/- 0.3 Volts
Coolant Temperature Sensor/Switch (For Computer)

Resistance:
At 20°C (68°F) ............................................................................................................................................................................ 2.21 - 2.69 K Ohms
At 80°C (176°F) ............................................................................................................................................................................ 264 - 328 K Ohms
Cooling System
Thermo Sensor A (On Radiator):
Operating Temperature:
Off -> On ........................................................................................................................................................................ 87 - 93°C (189 - 199°F)
On -> Off .......................................................................................................................................................................... 83°C (181°F) Or More
Thermo Sensor B (On Radiator):
Off -> On ...................................................................................................................................................................... 97 - 103°C (207 - 217°F)
On -> Off .......................................................................................................................................................................... 93°C (199°F) Or More
Thermo Sensor C (On Engine Coolant Outlet Fitting):
Off -> On ........................................................................................................................................................................ 108°C (226°F) Or More
On -> Off .................................................................................................................................................................... 112 - 118°C (234 - 244°F)
EGR Control Solenoid

Coil Current ............................................................................................................................................................................ 0.456 Amp or less at 12V
Resistance:
At 20°C (68°F) .......................................................................................................................................................................................... 36 - 44 Ohms
Electronic Brake Control Module

ABSCM (ABS Control Module):
Operating Voltage Range ................................................................................................................................................................... 9.0 - 16.2 Volts
Power Consumption ...................................................................................................................................................................... 150 mA Or Below
Control Fuse ................................................................................................................................................................................................. 10 Amps
Operating Temperature Range .............................................................................................................................................................. -40° to +80°C
Injector Resistance 13 - 16 Ohms @ 20 deg. C (68 deg. F)
Hydraulic Control Assembly - Antilock Brakes

Operating Voltage Range ..................................................................................................................................................................... 9.0 to 16.2 Volts
Rated Voltage .................................................................................................................................................................................................... 12 Volts
Motor Pump Fuse ............................................................................................................................................................................................. 30 Amps
Solenoid Fuse ................................................................................................................................................................................................... 20 Amps
Operating Temperature Range ............................................................................................................................................................... -40°C to 120°C
resistance
resistance
1998 Hyundai
Hyundai
SonataSonata L4-2.0L 225
L4-2.0L
Copyright ©
2011,
ALLDATA
10.40 Page
3
Between Terminals: 2-3 28-33 ohms at 20 deg C
2-1 28-33 ohms at 20 deg C
5-4 28-33 ohms at 20 deg C
5-6 28-33 ohms at 20 deg C
Spark Plug Cable

Spark Plug Cable
Cable Number Resistance
Number 1 Cable 5.8 K ohms
Primary Coil Resistance 0.86 +/- 0.09 ohms
Secondary Coil Resistance 12.1 +/- 1.8 K ohms
Ignition Timing 5 deg. +/- 2 deg. BTDC at curb idle
Sensor 2.33-2.97 K ohms at 20 deg C
Output
Output
Output Voltage @ Idle 1.7-2.3 V
Temperature Sensor (Gauge)

Resistance:
At 70°C (158°F) ............................................................................................................................................................................ 90.5 - 117.5 Ohms
At 115°C (239°F) ............................................................................................................................................................................ 21.3 - 26.3 Ohms
Between Terminals 1-4 3.5-6.5 K ohms
Wheel Speed Sensor

SERVICE SPECIFICATIONS
Service Standard:
Resistance (Between Wheel Speed Sensor Terminals):
Front .................................................................................................................................................................................. 1275 - 1495 Ohms
Rear ................................................................................................................................................................................... 1260 - 1540 Ohms
Voltage (Between Wheel Speed Sensor Terminals):
While Turning Wheel ................................................................................................................................................... AC Voltage Detected
Accelerator Arm Bracket Bolt Torque 8-12 Nm
Air Bag/Clock Spring Replacement

Air Bag/Clock Spring Replacement
Driver Side Air Bag (DAB) Steering Wheel Lock Nut 40 - 50 Nm
DAB Mounting Bolt 15 - 20 Nm
Air Cleaner Housing

Air Cleaner Body Installation Bolt ........................................................................................................................................... 8 - 10 Nm (6 - 7 ft. lbs.)
Alignment
Toe-In:
Front ................................................................................................................................................................................................... -3 mm to 3 mm
Rear .................................................................................................................................................................. 3 to -2 mm (+0.12 inch to -0.08 inch)
Camber:
Front ................................................................................................................................................................................................................ 0° ± 30'
Rear .............................................................................................................................................................................................................. -30' ± 30'
Maximum Camber Angle Difference Between:
LH and RH ......................................................................................................................................................................................................... 0° 30'
Caster (To Ground) ....................................................................................................................................................................................... 2° 40' ± 30'
King Pin Angle .................................................................................................................................................................................................... 13° 31'
Wheel Runout:
Radial:
Steel Wheel:
Average Of LH and RH .................................................................................................................................................. 0.6 mm (0.024 inch)
Aluminum Wheel ................................................................................................................................................................. 0.3 mm (0.012 inch)
Axial:
Steel Wheel ........................................................................................................................................................................... 1.0 mm (0.039 inch)
Aluminum Wheel ................................................................................................................................................................. 0.3 mm (0.012 inch)
Steering Angle:
Inside Wheel ............................................................................................................................................................................................. 39°67' ± 2°
Outside Wheel ................................................................................................................................................................................................... 32°21'
System Specifications
Type .............................................................................................................................................. Electronically Controlled 4-speed Full-Automatic
Gear Ratio
First ............................................................................................................................................................................................................... 2.551
Second ........................................................................................................................................................................................................... 1.488
Third .............................................................................................................................................................................................................. 1.000
Fourth ............................................................................................................................................................................................................ 0.685
Reverse .......................................................................................................................................................................................................... 2.176
Final Gear Ratio .................................................................................................................................................................................................. 4.350
Speedometer Gear Ratio ............................................................................................................................................................... Drive 36/Driven 29
Transfer Shaft End Play .............................................................................................................................................. 0 - 0.025 mm (0 - 0.0010 inch)
Transfer Idler Gear Preload ........................................................................................................................................................ 0.8 Nm (0.59 ft. lbs.)
Transfer Drive Gear End Play ....................................................................................................................................... 0 - 0.06 mm (0 - 0.0024 inch)
TORQUE SPECIFICATIONS
Indicator Panel Mounting Screw .................................................................................................................... 1.5 Nm Or More (1.1 ft. lbs. Or More)
Drain plug ........................................................................................................................................................................ 30 - 35 Nm (22 - 25 ft. lbs.)
Pressure Check Plug .............................................................................................................................................................. 8 - 10 Nm (6 - 7 ft. lbs.)
Pulse Generator Mounting Bolt ..................................................................................................................................... 10 - 12 Nm (7.5 - 8.5 ft. lbs.)
Bearing Retainer Screw ................................................................................................................................................... 17 - 22 Nm (13 - 15 ft. lbs.)
Lock Plate Bolt ................................................................................................................................................................ 48 - 60 Nm (35 - 43 ft. lbs.)
Manual Control Lever Nut ............................................................................................................................................... 17 - 21 Nm (13 - 15 ft. lbs.)
Manual Control Shaft Set Screw ............................................................................................................................................ 8 - 10 Nm (6 - 7 ft. lbs.)
Detent Spring Bolt ......................................................................................................................................................... 10 - 12 Nm (7.5 - 8.5 ft. lbs.)
Transaxle Range Switch ................................................................................................................................................ 10 - 12 Nm (7.5 - 8.5 ft. lbs.)
Sprag Rod Support Bolt ................................................................................................................................................... 20 - 27 Nm (15 - 19 ft. lbs.)
End Clutch Cover ..................................................................................................................................................................... 6 - 8 Nm (5 - 6 ft. lbs.)
Kickdown Servo Lock Nut .............................................................................................................................................. 25 - 32 Nm (18 - 23 ft. lbs.)
Transfer Shaft Lock Nut .......................................................................................................................................... 200 - 230 Nm (145 - 166 ft. lbs.)
Drive Plate-To-Converter Tightening Bolt ..................................................................................................................... 46 - 53 Nm (34 - 38 ft. lbs.)
Bell Housing, A/T
Bell Housing Cover To Transaxle ....................................................................................................................................... 15 - 22 Nm (11 - 16 ft. lbs.)
Bell Housing Cover To Engine Cylinder Block ........................................................................................................................ 8 - 10 Nm (6 - 7 ft. lbs.)
Clutch, A/T
Front Clutch Snap Ring Clearance .......................................................................................................................... 0.7 - 0.9 mm (0.028 - 0.035 inch)
Rear Clutch Snap Ring Clearance ........................................................................................................................... 0.4 - 0.6 mm (0.016 - 0.024 inch)
End Clutch Snap Ring Clearance .......................................................................................................................... 0.4 - 0.65 mm (0.016 - 0.024 inch)
Low Reverse Brake Snap Ring Clearance ...................................................................................................... 0.975 - 1.287 mm (0.039 - 0.050 inch)
One-Way Clutch Outer Race Bolt ............................................................................................................................................. 8 - 10 Nm (6 - 7 ft. lbs.)
Differential, Automatic Transaxle

Differential Case End Play ................................................................................................................................. 0 - 0.150 mm (0.0010 - 0.0059 inch)
Differential Side Gear And Pinion:
Backlash ................................................................................................................................................ 0.025 - 0.150 mm (0.0010 - 0.0059 inch)
Differential Drive Gear Bolt ...................................................................................................................................... 130 - 140 Nm (94 - 101 ft. lbs.)
Fluid Filter - A/T

Oil Filter Bolt ............................................................................................................................................................................... 5 - 7 Nm (4 - 5 ft. lbs.)
Transmission Pan Bolts 10 - 12 Nm (100 - 120 kg.cm., 7.5 - 8.5 lb.ft.)
Fluid Pump, A/T

Oil Pump Gear Side Clearance ..................................................................................................................... 0.01 - 0.048 mm (0.0004 - 0.0019 inch)
Pump housing-to-reaction shaft support bolt ................................................................................................................. 10 - 12 Nm (7.5 - 8.5 ft. lbs.)
Oil pump assembly mounting bolt ................................................................................................................................... 15 - 22 Nm (11 - 15 ft. lbs.)
Input Shaft, A/T

Input Shaft End Play ................................................................................................................................................... 0.3 - 1.0 mm (0.012 - 0.039 inch)
Selector Shaft, A/T

Selector Knob Set Screw ....................................................................................................................................... 2.0 Nm or more (1.5 ft. lbs. or more)
Shifter A/T
Selector Lever Mounting Screw .......................................................................................................................................... 14 - 20 Nm (10 - 14 ft. lbs.)
Torque Converter
Type ................................................................................................................................................................................................ With damper cloth
Engine stall speed .............................................................................................................................................................................. 2,500 + 200 rpm
Stall torque ratio ...................................................................................................................................................................................................... 1.9
Converter Housing Bolt ................................................................................................................................................... 19 - 23 Nm (14 - 16 ft. lbs.)
Transmission Cooler, A/T

Oil Cooler Connector ........................................................................................................................................................... 15 - 22 Nm (11 - 16 ft. lbs.)
Transmission Mount, A/T

Transaxle Mounting Bracket To Transaxle ......................................................................................................................... 60 - 80 Nm (43 - 57 ft. lbs.)
Transaxle Mounting Bracket To Body ................................................................................................................................ 40 - 50 Nm (39 - 36 ft. lbs.)
Transaxle Mounting Bolt
10 mm (0.40 inch) diameter bolt ...................................................................................................................................... 43 - 55 Nm (32 - 39 ft. lbs.)
8 mm (0.31 inch) diameter bolt ........................................................................................................................................ 30 - 35 Nm (22 - 25 ft. lbs.)
Valve Body, A/T

Valve Body Bolt .......................................................................................................................................................................... 4 - 6 Nm (3 - 4 ft. lbs.)
Valve Body Assembly Mounting Bolt ............................................................................................................................... 10 - 12 Nm (7.5 - 8.5 ft. lbs.)
Backup Lamp Switch

Backup Lamp Switch .......................................................................................................................................................... 30 - 35 Nm (22 - 25 ft. lbs.)
Torque Specifications
Lower Arm Ball Joint To Knuckle ..................................................................................................................................... 60 - 72 Nm (43 - 52 ft. lbs.)
Wear Limit
Ball Joint Rotating Torque:
Standard Value ...................................................................................................................................................... 2.5 - 8.5 Nm (1.8 - 6.3 ft. lbs.)
Fluid Types
In Ball Joint Of Lower Arm:
Front and Rear ................................................................................................................................ Valiant R-2 Grease Or POLY LUB GLY 801 K
Inside Surface and Lip Of Ball Joint Dust Cover:
Front and Rear ..................................................................................................................................................................................... Sunlight MB-2
FRONT BRAKE ROTOR/DISC
DIMENSIONS
Disc Outer Diameter ................................................................................................................................................................ 257 mm (10.118 inch)
Disc Thickness:
Minimum ............................................................................................................................................................................... 20 mm (0.787 inch)
Standard (New) ...................................................................................................................................................................... 22 mm (0.866 inch)
Total Runout:
Maximum .......................................................................................................................................................................... 0.06 mm (0.0024 inch)
REAR BRAKE ROTOR/DISC

DIMENSIONS
Disc Outer Diameter .................................................................................................................................................................. 260 mm (10.24 inch)
Disc Thickness:
Minimum .............................................................................................................................................................................. 10.5 mm (0.41 inch)
Standard (New) ........................................................................................................................................................................ 12 mm (0.47 inch)
Total Runout:
Maximum .......................................................................................................................................................................... 0.06 mm (0.0024 inch)
REAR BRAKE DRUM

DIMENSIONS
Inside Diameter:
Maximum ............................................................................................................................................................................ 230.6 mm (9.08 inch)
Standard (New)...................................................................................................................................................................... 228.6 mm (9.0 inch)
Brake Hose
Brake Hose To Front Caliper .......................................................................................................................................... 25 - 30 Nm (18 - 22 ft. lbs.)
Brake Line
Brake Tube Flare Nut ....................................................................................................................................................... 13 - 17 Nm (9 - 12 ft. lbs.)
Brake Master Cylinder

Type ............................................................................................................................................................................................................... Tandem
Inside Diameter ............................................................................................................................................................................. 25.4 mm (1.0 inch)
Master Cylinder To:
Booster Mounting Nut ........................................................................................................................................ 13.6 - 21.7 Nm (10 - 16 ft. lbs.)
Brake Pedal Assy

Brake Pedal Height:
From Top of Pedal To Toeboard .................................................................................................................... 176.0 - 181 mm (6.93 - 7.13 inch)
Brake Pedal Free Play ................................................................................................................................................ 4 - 10 mm (0.157 - 0.394 inch)
Brake Pedal To Floorboard Clearance:
When Pedal Is Depressed 50 kg (110 lbs.) Of:
Force ................................................................................................................................................................... 75 mm (2.95 inch) Or More
When Pedal Is Fully Depressed Without:
Brake Fluid ....................................................................................................................................................... 35 mm (1.378 inch) Or More
Stop Lamp Switch Outer Case To:
Pedal Stopper Clearance .................................................................................................................................. 0.5 - 1.0 mm (0.020 - 0.040 inch)
Brake Proportioning/Combination Valve

Cut-In Pressure:
Split Point ............................................................................................................................................................................... 3.63 MPa (526 psi)
Decompression Ratio .......................................................................................................................................................................................... 3.7:1
Proporting Valve Mounting Nut ................................................................................................................................. 13 - 22 Nm (9.6 - 16.2 ft. lbs.)
DIMENSIONS FRONT
Disc Thickness:
Minimum ............................................................................................................................................................................... 20 mm (0.787 inch)
Total Runout:
Maximum .......................................................................................................................................................................... 0.06 mm (0.0024 inch)
DIMENSIONS REAR
Disc Thickness:
Minimum .............................................................................................................................................................................. 10.5 mm (0.41 inch)
Total Runout:
Maximum .......................................................................................................................................................................... 0.06 mm (0.0024 inch)
Front
Cylinder Inside Diameter .......................................................................................................................................................... 57.2 mm (2.252 inch)
Bleeder Screw ..................................................................................................................................................................... 7 - 13 Nm (5 - 10 ft. lbs.)
Caliper Guide Rod Bolt .................................................................................................................................................. 22 - 32 Nm (16 - 24 ft. lbs.)
Caliper Assembly To Knuckle ........................................................................................................................................ 69 - 85 Nm (51 - 63 ft. lbs.)
Rear
Bleeder Tube Screw ...................................................................................................................................................... 8 - 20 Nm (5.9 - 14.7 ft. lbs.)
Front Brake Pad Thickness 11 mm
Rear Disc Brake Pad Thickness 10 mm
Front Disc Brake Pad Thickness Service Limit 2.0 mm
Rear Disc Brake Pad Thickness Service Limit 2.0 mm
Front
DIMENSIONS
Disc Thickness:
Minimum ............................................................................................................................................................................... 20 mm (0.787 inch)
Total Runout:
Maximum .......................................................................................................................................................................... 0.06 mm (0.0024 inch)
Rear
DIMENSIONS
Disc Thickness:
Minimum .............................................................................................................................................................................. 10.5 mm (0.41 inch)
Total Runout:
Maximum .......................................................................................................................................................................... 0.06 mm (0.0024 inch)
Drum Inside Diameter:
2.0L ...................................................................................................................................................................................... 225 mm (8.858 inch)
3.0L ....................................................................................................................................................................................... 228.6 mm (9.0 inch)
Service Limit (Maximum):
2.0L ................................................................................................................................................................................ 227 mm (8.936 inch)
3.0L ............................................................................................................................................................................... 230.6 mm (9.08 inch)
Out Of Round Of Brake Drum:
Service Limit ......................................................................................................................................................................................... 0.015 mm
Backing Plate
Backing Plate Mounting Nut .......................................................................................................................................... 50 - 60 Nm (37 - 44 ft. lbs.)
Brake Drum
Drum Inside Diameter:
2.0L ...................................................................................................................................................................................... 225 mm (8.858 inch)
3.0L ....................................................................................................................................................................................... 228.6 mm (9.0 inch)
Service Limit (Maximum):
2.0L ................................................................................................................................................................................ 227 mm (8.936 inch)
3.0L ............................................................................................................................................................................... 230.6 mm (9.08 inch)
Out Of Round Of Brake Drum:
Service Limit ......................................................................................................................................................................................... 0.015 mm
Brake Shoe
Brake Lining Thickness:
2.0L ..................................................................................................................................................................................... 5.89 mm (0.231 inch)
3.0L ..................................................................................................................................................................................... 4.45 mm (0.175 inch)
Service Limit:
2.0L ................................................................................................................................................................................. 0.8 mm (0.031 inch)
3.0L ................................................................................................................................................................................. 1.5 mm (0.031 inch)
Wheel Cylinder
Cylinder Inside Diameter .......................................................................................................................................................... 20.6 mm (0.811 inch)
Wheel Cylinder To Piston Clearance ....................................................................................................................................... 0.15 mm (0.006 inch)
Bleeder Tube Screw ...................................................................................................................................................... 8 - 20 Nm (5.9 - 14.7 ft. lbs.)
Wheel Cylinder Mounting Bolt ..................................................................................................................................... 12 - 18 Nm (8.8 - 13 ft. lbs.)
Hydraulic Control Assembly - Antilock Brakes

Modulator Mounting Bolt ............................................................................................................................................... 17 - 26 Nm (12 - 19 ft. lbs.)
Parking Brake Lever

Parking Brake Lever Stroke When Lever Assembly Is Pulled:
With 196 N (44 lbs. Force): ................................................................................................................................................................ 8 - 9 Clicks
Vacuum Brake Booster

Type ................................................................................................................................................................. Vacuum Type With Tandem Booster
Effective Diameter ..................................................................................................................................................... 203.2 + 228.6 mm (8 + 9 inch)
Boosting Ratio ..................................................................................................................................................................................................... 5.6:1
Booster Push Rod To:
Master Cylinder Piston Clearance ................................................................................................................................ 0 (at 500 mmHg vacuum)
Brake Booster Mounting Nut .......................................................................................................................................... 21 - 28 Nm (15 - 21 ft. lbs.)
Brake Booster Vacuum Hose Fitting To:
Manifold ................................................................................................................................................................... 15 - 18 Nm (11 - 13 ft. lbs.)
Wheel Speed Sensor

Air Gap Between Sensor and Tone Wheel Teeth:
Front ................................................................................................................................................................. 0.2 - 1.1 mm (0.008 - 0.043 inch)
Rear .................................................................................................................................................................. 0.2 - 1.2 mm (0.008 - 0.047 inch)
Limit
Diaphragm Spring End Height Difference .............................................................................................................................. 0.5 mm (0.02 inch)
TIGHTENING SPECIFICATIONS
Clutch Cover Assembly ................................................................................................................................................. 15-22 Nm (11-16 ft. lbs.)
Clutch Disc, M/T

Clutch Disc:
Type ......................................................................................................................................................................... Single Dry With Diaphragm
Facing Diameter ........................................................................................................................ (Inside x Inside) 225 x 150 mm (8.9 x 5.9 inch)
Clutch Disc Thickness [When Free] ....................................................................................................................... 8.3 - 8.9 mm (0.326 - 0.350 inch)
Clutch Disc Rivet Sink ................................................................................................................................................................ 0.3 mm (0.012 inch)
Clutch Master Cylinder

Inside Diameter .................................................................................................................................................................... 15.87 mm (0.62 inch)
Cylinder Clearance To Piston .............................................................................................................................................. 0.15 mm (0.006 inch)
Clutch Master Cylinder Mounting Bolt ............................................................................................................................. 10 - 15 Nm (7 - 11 ft. lbs.)
Clutch Master Cylinder Push Rod Lock Nut ..................................................................................................................... 10 - 15 Nm (7 - 11 ft. lbs.)
Clutch Pedal Assembly

Clutch Pedal Free Play:
Including Clevis Pin Free Play ................................................................................................................................. 6 - 13 mm (0.24 - 0.51 inch)
Clutch Pedal Stroke ...................................................................................................................................................................... 150 mm (5.90 inch)
Clutch Pedal To Pedal Support Member:
Clutch Pedal Bracket .................................................................................................................................................. 25 - 35 Nm (18 - 25 ft. lbs.)
Clutch Slave Cylinder

Clutch Release Cylinder
Inside Diameter .................................................................................................................................................................... 20.64 mm (0.81 inch)
Cylinder Clearance To Piston .............................................................................................................................................. 0.15 mm (0.006 inch)
Clutch Release Cylinder Mounting Bolt .......................................................................................................................... 20 - 27 Nm (14 - 20 ft. lbs.)
Clutch Release Cylinder Union Bolt .............................................................................................................................................. 25 Nm (18 ft. lbs.)
Hydraulic Hose, Clutch

Clutch Tube Flare Nut ....................................................................................................................................................... 13 - 17 Nm (9 - 12 ft. lbs.)
Pressure Plate
Clutch Cover Assembly
Type ................................................................................................................................................................................. Diaphragm Spring Strap
Setting Load ................................................................................................................................................ 4171 - 4563 Nm (937 - 1025 ft. lbs.)
Diaphragm Spring End Height Difference .................................................................................................................................... 0.5 mm (0.02 inch)
Clutch Cover Assembly ................................................................................................................................................... 15 - 22 Nm (11 - 16 ft. lbs.)
Coil Spring
Coil Spring Free Height And Identification Color:
Model:
2.0GL +M/T -A/C +G/S:
Free Height .................................................................................................................................................................. 381 mm (15 inch lbs.)
Identification Color .................................................................................................................................................................... Green 1 Line
2.0GLS +A/T -A/C +G/S:
Free Height ................................................................................................................................................................. 389.7 mm (15.34 inch)
2.0GLS +A/C +G/S:
3.0GLS +G/S:
Identification Color .......................................................................................................................................................... Green 1 Red 1 Line
2.0GL +M/T:
Identification Color ...................................................................................................................................................................... Blue 1 Line
2.0GL +A/T:
3.0GL:
3.0GLS -G/S:
2.0GLS +A/C -G/S:
2.0GLS -A/L -G/S:
- GL, GLS: Trim Level

- M/T: With Manual Transaxle
- A/T: With Automatic Transaxle
- A/C: With Air Conditioning
- G/S: Gas Shock Absorber
Torque 20-40 Nm
Sealant Loctite 962T Or Equivalent
Engine Coolant Outlet Fiting Attaching Bolt ..................................................................................................................... 17 - 20 Nm (12 - 14 ft. lbs.)
Water Pump
Engine Coolant Pump Pulley Bolt ............................................................................................................................................ 8 - 10 Nm (6 - 7 ft. lbs.)
Engine Coolant Pump To Cylinder Block:
Bolt Head Mark "4" .......................................................................................................................................................... 12 - 15 Nm (9 - 11 ft. lbs.)
Bolt Head Mark "7" ........................................................................................................................................................ 20 - 27 Nm (14 - 20 ft. lbs.)
Crankshaft Position Sensor

Crankshaft Position Sensor ..................................................................................................................................................... 10 - 13 Nm (7 - 9 ft. lbs.)
Front
Crossmember Inner Sleeve Extension:

Bushing A: 9.2 - 10.2 mm (0.36 - 0.40 inch)
Bushing B: 8.5 - 9.5 mm (0.33 - 0.35 inch)
Rear
Inner Pipe Projection:

Standard Value (A): 8.5 - 9.5 mm (0.33 - 0.37 inch)
Retaining Bolts 15-22 Nm
Tightening Specifications (Part 1 Of 3)



Tightening Sequence
Drive Plate-To-Converter (Flex Plate) Tightening Bolt ............................................................................................ 46 - 53 Nm (34 - 38 ft. lbs.)
Flywheel ............................................................................................................................................................. 130 - 140 Nm (94 - 101 ft. lbs.)
Fig. 8 Camshaft Bearing Cap Tightening Sequence
Camshaft Bearing Cap Bolt Tightening Sequence

Torque .................................................................................................................................................... 19-21 Nm (190 - 210 kg.cm., 14 - 15 lb.ft.)
Camshaft Bearing

Timing Gear
Timing Gear
Camshaft Sprocket Bolt Torque: 80 - 100 Nm, (800 - 1000 kg.cm., 58 - 72 lb.ft.)
General Torque Specifications



Drive Plate-To-Converter (Flex Plate) Tightening Bolt .................................................................................................. 46 - 53 Nm (34 - 38 ft. lbs.)
Flywheel Bolts ......................................................................................................................................................... 130 - 140 Nm (94 - 101 ft. lbs.)
Main Bearing Cap Bolts .......................................................................................................................... 65-70 Nm (650-700 kg. cm, 47-51 ft. lbs.)
NOTE:
- Using a sequence of center cap, No.2 cap, No.4 cap, front cap and rear cap.
- Cap bolts should be tightened evenly in 4 to 5 stages before they are tightened to specified torque.
Cylinder Block Specifications

Cylinder Bore ............................................................................................................................................. 85.00 - 85.03 mm (3.3465 - 3.3476 inch)
Out-Of-Roundness And Taper Of:
Cylinder Bore .................................................................................................................................................. Less Than 0.01 mm (0.0004 inch)
Flatness Of Gasket Surface:
Specification .......................................................................................................................................................................... Less Than 0.05 mm
Limit ..................................................................................................................................................................................... 0.1 mm (0.004 inch)
Piston Stroke .................................................................................................................................................................................. 88 mm (3.46 inch)
Compression Ratio ................................................................................................................................................................................................. 9.0
MAIN BEARINGS
OIL CLEARANCE SPECIFICATION
Standard Value ............................................................................................................................................. 0.02-0.05 mm (0.0008-0.0020 inch)
Wear Limit ............................................................................................................................................................................ 0.1 mm (0.004 inch)
THRUST BEARING (CRANKSHAFT END PLAY) SPECIFICATIONS

Wear Limit ........................................................................................................................................................................ 0.25 mm (0.0098 inch)
Crankshaft Pulley Torque

Crankshaft Sprocket Bolt ................................................................................................................................................ 110 - 130 Nm (80 - 94 ft. lbs.)
Connecting Rod Bearing Clearance and Specifications

Connecting Rod Bearing:
Oil Clearance:
Specification ............................................................................................................................................ 0.02 - 0.05 mm (0.0008 - 0.0020 inch)
Limit ..................................................................................................................................................................................... 0.1 mm (0.004 inch)
Connecting Rod Service Specifications

Connecting Rod:
Bend ........................................................................................................................... 0.05 mm (0.0020 inch) Or Less Per 100 mm (3.937 inch)
Twist ............................................................................................................................... 0.1 mm (0.004 inch) Or Less Per 100 mm (3.937 inch)
Big End To Crankshaft Side Clearance:
Limit ................................................................................................................................................................................... 0.4 mm (0.0157 inch)
TORQUE SPECIFICATION
Connecting Rod Cap Bolt ................................................................................................................................................... 50 - 53 Nm (36 - 38 ft. lbs.)
Connecting Rod Cap Nuts

Connecting Rod Cap Nuts Torque: 50 - 53 Nm (500 - 530 kg.cm., 36 - 38 lb.ft.)
Main Bearing Bore Dimensions and Cap Torque


Bearing Cap Bolts .............................................................................................................................. 65-70 Nm (650-700 kg. cm, 47-51 ft. lbs.)
NOTE:
Piston Dimensions and Clearances

Piston:
Outside Diameter ....................................................................................................................................... 84.97 - 85.00 mm (3.3453 - 3.3465 inch)
Piston To Cylinder Clearance ........................................................................................................................ 0.01 - 0.03 mm (0.0004 - 0.0012 inch)
Ring Groove Width:
No.1 ......................................................................................................................................................... 1.22 - 1.24 mm (0.0480 - 0.0488 inch)
No.2 ......................................................................................................................................................... 1.52 - 1.54 mm (0.0598 - 0.0606 inch)
Oil ............................................................................................................................................................ 3.01 - 3.03 mm (0.1185 - 0.1193 inch)
Service Size:
................................................................................................................. 0.25, 0.50, 0.75, 1.00 mm (0.010, 0.020, 0.030, 0.040 inch) Oversize
Piston Ring Gap and Groove Clearances

Piston Ring:
Side Clearance:
No.1 and No.2:
Specification ...................................................................................................................................... 0.03 - 0.07 mm (0.0012 - 0.0028 inch)
Limit ............................................................................................................................................................................... 0.1 mm (0.004 inch)
End Gap:
No.1:
Limit ............................................................................................................................................................................... 0.8 mm (0.031 inch)
No.2:
Limit ............................................................................................................................................................................... 0.8 mm (0.031 inch)
Oil Ring Side Rail:
Limit ............................................................................................................................................................................... 1.0 mm (0.040 inch)
Service Size:
Specification ............................................................................................ 0.25, 0.50, 0.75, 1.00 mm (0.010, 0.020, 0.030, 0.039 inch) Oversize
Balance Shaft
Right Silent Shaft:
Front Journal Diameter .......................................................................................................................... 41.959 - 41.975 mm (1.6519 - 1.6526 inch)
Rear Journal Diameter ........................................................................................................................... 40.951 - 40.967 mm (1.6122 - 1.6129 inch)
Oil Clearance:
Front ................................................................................................................................................... 0.020 - 0.0061 mm (0.0008 - 0.0024 inch)
Rear ...................................................................................................................................................... 0.050 - 0.091 mm (0.0020 - 0.0036 inch)
Left Silent Shaft:
Front Journal Diameter .......................................................................................................................... 18.467 - 18.480 mm (0.7270 - 0.7276 inch)
Rear Journal Diameter ........................................................................................................................... 40.959 - 40.975 mm (1.6126 - 1.6132 inch)
Oil Clearance:
Front ..................................................................................................................................................... 0.020 - 0.054 mm (0.0008 - 0.0021 inch)
Rear ...................................................................................................................................................... 0.042 - 0.083 mm (0.0017 - 0.0033 inch)
Connecting Rod Bearing

Connecting Rod Bearing:
Oil Clearance:
Limit ..................................................................................................................................................................................... 0.1 mm (0.004 inch)
Connecting Rod Service Specifications

Connecting Rod:
Bend ........................................................................................................................... 0.05 mm (0.0020 inch) Or Less Per 100 mm (3.937 inch)
Twist ............................................................................................................................... 0.1 mm (0.004 inch) Or Less Per 100 mm (3.937 inch)
Big End To Crankshaft Side Clearance:
Limit ................................................................................................................................................................................... 0.4 mm (0.0157 inch)
TORQUE SPECIFICATION
Connecting Rod Cap Bolt ................................................................................................................................................... 50 - 53 Nm (36 - 38 ft. lbs.)

Connecting Rod Cap Nuts Torque: 50 - 53 Nm (500 - 530 kg.cm., 36 - 38 lb.ft.)
Crankshaft Gear/Sprocket
Crankshaft Sprocket Bolt ................................................................................................................................................ 110 - 130 Nm (80 - 94 ft. lbs.)
Crankshaft Main Bearing


Bearing Cap Bolts .............................................................................................................................. 65-70 Nm (650-700 kg. cm, 47-51 ft. lbs.)
NOTE:
Crankshaft, Engine
Pin Outside Diameter ................................................................................................................................. 44.980 - 44.995 mm (1.7709 - 1.7715 inch)
Journal Outside Diameter .......................................................................................................................... 56.980 - 56.995 mm (2.2433 - 2.2439 inch)
Out Of Roundness Of Journal And:
Pin ....................................................................................................................................................................... Less Than 0.015 mm (0.0006 inch)
Taper Of Journal And Pin ....................................................................................................................................... Less Than 0.005 mm (0.0002 inch)
End Play:
Specification .................................................................................................................................................. 0.05 - 0.18 mm (0.0020 - 0.0071 inch)
Limit ....................................................................................................................................................................................... 0.25 mm (0.0098 inch)
Harmonic Balancer - Crankshaft Pulley

Crankshaft Pulley To:
Crankshaft Sprocket ........................................................................................................................................................ 20 - 30 Nm (14 - 22 ft. lbs.)
Piston Pin, Engine

Piston Pin Press-In Load ...................................................................................................................................... 7,500 - 17,500 N (1,653 - 3,858 lbs.)
Piston Ring, Engine

Piston Ring:
Side Clearance:
No.1 and No.2:
Limit ............................................................................................................................................................................... 0.1 mm (0.004 inch)
End Gap:
No.1:
Limit ............................................................................................................................................................................... 0.8 mm (0.031 inch)
No.2:
Limit ............................................................................................................................................................................... 0.8 mm (0.031 inch)
Oil Ring Side Rail:
Limit ............................................................................................................................................................................... 1.0 mm (0.040 inch)
Service Size:
Specification ............................................................................................ 0.25, 0.50, 0.75, 1.00 mm (0.010, 0.020, 0.030, 0.039 inch) Oversize
Piston, Engine
Piston:
Outside Diameter ....................................................................................................................................... 84.97 - 85.00 mm (3.3453 - 3.3465 inch)
Piston To Cylinder Clearance ........................................................................................................................ 0.01 - 0.03 mm (0.0004 - 0.0012 inch)
Ring Groove Width:
No.1 ......................................................................................................................................................... 1.22 - 1.24 mm (0.0480 - 0.0488 inch)
No.2 ......................................................................................................................................................... 1.52 - 1.54 mm (0.0598 - 0.0606 inch)
Oil ............................................................................................................................................................ 3.01 - 3.03 mm (0.1185 - 0.1193 inch)
Service Size:
................................................................................................................. 0.25, 0.50, 0.75, 1.00 mm (0.010, 0.020, 0.030, 0.040 inch) Oversize
Rear Engine Plate

Oil Seal Case Bolt ................................................................................................................................................................... 10 - 12 Nm (7 - 9 ft. lbs.)
General Specifications
Part 1 of 3
Part 2 of 3
Part 3 of 3
Cylinder Head Bolt Torque and Sequence




Tightening Sequence

Camshaft Bearing Cap Torque and Sequence

Timing Gear
Timing Gear
Camshaft Sprocket Bolt Torque: 80 - 100 Nm, (800 - 1000 kg.cm., 58 - 72 lb.ft.)
Intake Manifold Torque and Sequence

Intake Manifold Stay .......................................................................................................................................................... 25 - 30 Nm (18 - 22 ft. lbs.)
Intake Manifold Mounting Bolts (M8) ............................................................................................................................... 15 - 20 Nm (11 - 14 ft. lbs.)
Intake Manifold Mounting Nut and Bolt ............................................................................................................................ 30 - 42 Nm (22 - 30 ft. lbs.)
Throttle Body To Intake Manifold ......................................................................................................... 15 - 22 Nm (150 - 220 kg.cm., 11 - 16 ft. lbs.)
Exhaust Manifold Torque and Sequence

Exhaust Manifold Nuts To:
Engine ............................................................................................................................................................................. 25 - 30 Nm (18 - 22 ft. lbs.)
Heat Protector Bolt To Exhaust Manifold ............................................................................................................................ 12 - 15 Nm (9 - 11 ft. lbs.)
Intake Valves Hydraulic - Not Adjustable
Exhaust Valves Hydraulic - Not Adjustable
Valve Seat
Valve Seat:
Width Of Seat Contact ........................................................................................................................................... 0.9 - 1.3 mm (0.035 - 0.051 inch)
Seat Angle ................................................................................................................................................................................................... 44 - 44.5°
Service Size .............................................................................................................................. 0.3 mm (0.012 inch), 0.6 mm (0.024 inch) Oversize
A/C Drive Belt

A/C Drive Belt
Inspection New Used
Deflection Approx. 8.0 mm 5.0-5.5 mm 6.0-7.0 mm
Tension 25-50 kgf 65 ± 5 kgf 36 ± 4 kgf
Power Steering
Drive Belt Tension (Under 98N (22 lbs.) Force):
Deflection ....................................................................................................................................................................... 7 - 10 mm (0.28 - 0.39 inch)
Engine Oil Drain Plug

Drain plug ........................................................................................................................................... 35 - 45 Nm (350 - 450 kgs.cm, 25 - 33 ft. lbs.)
Intake Manifold
Intake Manifold Stay .......................................................................................................................................................... 25 - 30 Nm (18 - 22 ft. lbs.)
Intake Manifold Mounting Bolts (M8) ............................................................................................................................... 15 - 20 Nm (11 - 14 ft. lbs.)
Intake Manifold Mounting Nut and Bolt ............................................................................................................................ 30 - 42 Nm (22 - 30 ft. lbs.)
Throttle Body To Intake Manifold ......................................................................................................... 15 - 22 Nm (150 - 220 kg.cm., 11 - 16 ft. lbs.)
Oil Pan, Engine

Oil Pan ........................................................................................................................................................................................ 6 - 8 Nm (4 - 6 ft. lbs.)
Oil Pick Up/Strainer

Oil Screen ........................................................................................................................................................................... 15 - 22 Nm (11 - 16 ft. lbs.)
Oil Pressure Sender

Oil Pressure Switch ............................................................................................................................................................. 8 - 12 Nm (5.8 - 8.7 ft. lbs.)
Tip Clearance:
Drive Gear:
Limit ........................................................................................................................................................................... 0.25 mm (0.0098 inch)
Driven Gear:
Limit ........................................................................................................................................................................... 0.25 mm (0.0098 inch)
Side Clearance:
Drive Gear:
Limit ........................................................................................................................................................................... 0.25 mm (0.0098 inch)
Driven Gear:
Limit ........................................................................................................................................................................... 0.25 mm (0.0098 inch)
Relief Spring:
Free Length ......................................................................................................................................................................... 46.6 mm (1.835 inch)
Load (61 N (13.5 lbs.) ........................................................................................................................................................ 40.1 mm (1.579 inch)
Oil Pump Sprocket Nut ................................................................................................................................................... 50 - 60 Nm (36 - 43 ft. lbs.)
Front Case Bolt:
M8 x 30 ..................................................................................................................................................................... 27 - 34 Nm (20 - 25 ft. lbs.)
Except M8 x 30 ......................................................................................................................................................... 20 - 27 Nm (14 - 20 ft. lbs.)
Driven Gear Bolt ............................................................................................................................................................. 34 - 40 Nm (25 - 29 ft. lbs.)
Oil Pressure Regulator Valve

Oil Relief Valve Plug ...................................................................................................................................................... 40 - 50 Nm (29 - 36 ft. lbs.)
Timing Belt
Timing Belt
Timing Belt Replacement Interval 60,000 miles (96,000 km)
Timing Belt Idler Pulley

Idle Pulley Bolt ................................................................................................................................................................... 34 - 42 Nm (23 - 30 ft. lbs.)
Timing Belt "A" (Camshaft)

TENSIONER SPECIFICATIONS
Maximum Rod Protrusion ....................................................................................................................................................... 12 mm (0.47 inch)
Mounting Bolt .................................................................................................................................... 20-27 Nm (200 270 kg. cm, 14-20 ft. lbs.)
Timing Belt "B" (Balance Shaft)

Mounting Bolt .................................................................................................................................... 15-22 Nm (150-220 kg. cm, 11-16 ft. lbs.)
Timing Cover
Timing Belt Upper Cover ....................................................................................................................................................... 10 - 12 Nm (7 - 9 ft. lbs.)
Timing Belt Lower Cover ....................................................................................................................................................... 10 - 12 Nm (7 - 9 ft. lbs.)
Timing Belt Rear Right Cover ................................................................................................................................................ 10 - 12 Nm (7 - 9 ft. lbs.)
Timing Belt Rear Left Cover (Lower) Bolt and Securing Left:
Engine Support Bracket .................................................................................................................................................. 30 - 42 Nm (22 - 30 ft. lbs.)
Timing Belt Rear Left Cover (Upper) ..................................................................................................................................... 10 - 12 Nm (7 - 9 ft. lbs.)
Hanger Bolt To:
Body .................................................................................................................................................................................. 10 - 15 Nm (7 - 11 ft. lbs.)
Main Muffler ..................................................................................................................................................................... 10 - 15 Nm (7 - 11 ft. lbs.)
Exhaust Manifold
Exhaust Manifold Nuts To:
Engine ............................................................................................................................................................................. 25 - 30 Nm (18 - 22 ft. lbs.)
Heat Protector Bolt To Exhaust Manifold ............................................................................................................................ 12 - 15 Nm (9 - 11 ft. lbs.)
Exhaust Pipe
Front Exhaust Pipe:
Support Bracket Bolt ...................................................................................................................................................... 30 - 42 Nm (22 - 30 ft. lbs.)
To Exhaust Manifold ...................................................................................................................................................... 30 - 40 Nm (22 - 29 ft. lbs.)
Clamp Bolt ...................................................................................................................................................................... 20 - 30 Nm (14 - 22 ft. lbs.)
To Catalytic Converter .................................................................................................................................................... 40 - 60 Nm (29 - 43 ft. lbs.)
Center Exhaust Pipe Nuts To:
Catalytic Converter ......................................................................................................................................................... 30 - 40 Nm (22 - 29 ft. lbs.)
Center Exhaust Pipe Bolts To:
Bracket .............................................................................................................................................................................. 10 - 15 Nm (7 - 11 ft. lbs.)
Main Muffler ................................................................................................................................................................... 30 - 40 Nm (22 - 29 ft. lbs.)
Exhaust Resonator
Resonator Mounting:
Bolt ....................................................................................................................................................................................... 8 - 10 Nm (6 - 7 ft. lbs.)
Nut ........................................................................................................................................................................................ 8 - 10 Nm (6 - 7 ft. lbs.)
Flex Plate
Drive Plate-To-Converter Tightening Bolt ..................................................................................................................... 46 - 53 Nm (34 - 38 ft. lbs.)
Flywheel
Flywheel .................................................................................................................................................................... 130 - 140 Nm (94 - 101 ft. lbs.)
Fuel Line Fittings 25-35 Nm
High Pressure Fitting @ Filter 25-35 Nm
High Pressure Fitting @ Fuel Tank 30-40 Nm
Installation Bolt 7-11 Nm
Fuel Rail
Fuel High Pressure Hose To:
Delivery Pipe .......................................................................................................................................................................... 4 - 6 Nm (3 - 4 ft. lbs.)
Delivery Pipe Bolt To Engine ................................................................................................................................................. 10 - 13 Nm (7 - 9 ft. lbs.)
Sender And Pump Retaining Screws 2-3 Nm
Drain Plug 15-25 Nm
High Pressure Fuel Line Fitting 30-40 Nm
Tighten To 25-35 Nm
Clutch Air Gap 0.014 - 0.030 in.
Idle Speed 750 +/- 100 rpm

Ignition Coil
Ignition Coil Bolts .............................................................................................................................................................. 20 - 27 Nm (14 - 20 ft. lbs.)
Ignition Control Module

Power Transistor Bolts ............................................................................................................................................................ 10 - 12 Nm (7 - 9 ft. lbs.)
Ignition Switch
Ignition Lock Switch ............................................................................................................................................................. 8 - 10 Nm (6 - 7 ft. lbs.)
Basic Ignition Timing 5 +/- 2 deg BTDC
Actual Ignition Timing 15 deg BTDC
Torque 4-7 Nm
Service
Type .............................................................................................................................................................................................. 5-Speed Floor Shift
Gear Ratio
First ............................................................................................................................................................................................................... 3.090
Second ........................................................................................................................................................................................................... 1.833
Third .............................................................................................................................................................................................................. 1.217
Fourth ............................................................................................................................................................................................................ 0.888
Fifth ............................................................................................................................................................................................................... 0.731
Reverse .......................................................................................................................................................................................................... 3.166
Final Gear Ratio .................................................................................................................................................................................................. 4.672
Speedometer Gear Ratio (Driven/Drive) ............................................................................................................................................................. 29/36
Snap Ring
SNAP RING FOR ADJUSTMENT AND SPACER
M/T Torque Data

Rear Cover Bolt .................................................................................................................................................................. 15 - 22 Nm (11 - 15 ft. lbs.)
Poppet Plug ......................................................................................................................................................................... 30 - 42 Nm (22 - 30 ft. lbs.)
Speedometer Sleeve Bolt ................................................................................................................................................ 3.0 - 5.0 Nm (2.5 - 3.5 ft. lbs.)
Stopper Bracket Bolt ........................................................................................................................................................... 15 - 22 Nm (11 - 15 ft. lbs.)
Restriction Ball Assembly .................................................................................................................................................. 30 - 35 Nm (22 - 25 ft. lbs.)
Bearing Retainer Bolt ......................................................................................................................................................... 15 - 22 Nm (11 - 15 ft. lbs.)
Interlock Plate Bolt ............................................................................................................................................................. 20 - 27 Nm (15 - 19 ft. lbs.)
Bell Housing, M/T

Bell Housing Cover To:
Transaxle ......................................................................................................................................................................... 15 - 22 Nm (11 - 16 ft. lbs.)
Engine ................................................................................................................................................................................. 10 - 12 Nm (7 - 9 ft. lbs.)
Case, M/T
Transaxle Case Tightening Bolt .......................................................................................................................................... 35 - 42 Nm (36 - 30 ft. lbs.)
Differential, Manual Transaxle

Differential Case End Play ...................................................................................................................... 0.05T - 0.10T mm (0.002T - 0.0039T inch)
Differential Side Gear And:
Pinion Backlash .......................................................................................................................................... 0.25 - 0.15 mm (0.001 - 0.0006 inch)
Differential Drive Gear Bolt ..................................................................................................................................... 130 - 140 Nm (94 - 101 ft. lbs.)
T: Indicates tightening of - (minus) direction of endplay.

L: Indicates loosening of + (plus) direction of endplay.
Drain Plug, M/T

Drain Plug ........................................................................................................................................................................... 30 - 35 Nm (22 - 25 ft. lbs.)
Fill Plug, M/T

Filler Plug ........................................................................................................................................................................... 30 - 35 Nm (22 - 25 ft. lbs.)
Input Shaft, M/T

Front Bearing End Play ......................................................................................................................... 0.01T - 0.12L mm (0.0004T - 0.0047L inch)
Rear Bearing End Play .......................................................................................................................... 0.01T - 0.09L mm (0.0004T - 0.0036L inch)
Input Shaft Lock Nut .............................................................................................................................................. 140 - 160 Nm (102 - 115 ft. lbs.)
T: Indicates tightening of - (minus) direction of endplay

L: Indicates loosening of + (plus) direction of endplay
Intermediate Shaft, M/T

Intermediate Shaft Front Bearing End Play .......................................................................................... 0.01T - 0.11L mm (0.0004T - 0.0044L inch)
Intermediate Shaft Rear Bearing End Play .............................................................................................. 0.05T - 0.10T mm (0.002T - 0.0039T inch)
Intermediate Shaft Lock Nut ................................................................................................................................... 140 -160 Nm (102 - 115 ft. lbs.)

Output Shaft, M/T

Output Shaft Bearing End Play ................................................................................................................... 0.05T - 0.10T mm (0.002T - 0.0039T inch)

Reverse Idler Gear

Reverse Idler Gear Shaft Bolt ............................................................................................................................................. 43 - 55 Nm (32 - 39 ft. lbs.)
Shifter M/T
Shift Lever To Lever ........................................................................................................................................................... 19 - 28 Nm (14 - 20 ft. lbs.)
Lever To Bracket Assembly ............................................................................................................................................... 19 - 28 Nm (14 - 20 ft. lbs.)
Reverse Shift Lever Assembly Installation Bolt ................................................................................................................. 15 - 22 Nm (11 - 15 ft. lbs.)
Synchronizer Ring, M/T

Synchronizer Ring And Clutch Gear Clearance ................................................................................................................................ 0.5 mm (0.02 inch)
Transmission Mount, M/T

Transaxle Mounting Bolt:
10 mm (0.39 inch) Diameter Bolt ................................................................................................................................... 43 - 55 Nm (32 - 39 ft. lbs.)
8 mm (0.31 inch) Diameter Bolt ..................................................................................................................................... 30 - 35 Nm (22 - 25 ft. lbs.)
Torque 40-50 Nm
PCV Valve 8-12 Nm
Power Steering Fluid Reservoir

Oil Reservoir Installation Bolt ............................................................................................................................................. 9 - 14 Nm (6.5 - 10 ft. lbs.)
Oil Reservoir Bracket Mounting Bolt .................................................................................................................................. 9 - 14 Nm (6.5 - 10 ft. lbs.)
Power Steering Line/Hose

Cooler Tube Clamp Mounting Bolt:
MANDO ........................................................................................................................................................................... 4 - 6 Nm (2.9 - 4.3 ft. lbs.)
Tube Clip and Tube Bracket ................................................................................................................................................ 9 - 14 Nm (6.5 - 10 ft. lbs.)
Pressure Hose Bracket Mounting Bolt ................................................................................................................................. 9 - 14 Nm (6.5 - 10 ft. lbs.)
Hose Clamp .......................................................................................................................................................................... 3 - 5 Nm (2.2 - 3.6 ft. lbs.)
Power Steering Pump

Oil Pump:
Type ..................................................................................................................................................................................................... Vane Type
Displacement ............................................................................................................................................... 9.6 cm3/rev. (0.586 cubic inch/rev.)
Pressure Hose To Oil Pump:
Jam Nut ..................................................................................................................................................................... 16 - 24 Nm (12 - 17 ft. lbs.)
Oil Pump Mounting Bolt ................................................................................................................................................ 25 - 33 Nm (18 - 24 ft. lbs.)
Heat Protector Mounting Bolt ......................................................................................................................................... 45 - 55 Nm (32 - 40 ft. lbs.)
Oil Pump Bracket Mounting Bolt ................................................................................................................................... 25 - 33 Nm (18 - 24 ft. lbs.)
Pump Cover To Pump Body ........................................................................................................................................... 33 - 43 Nm (24 - 31 ft. lbs.)
Suction Connector To Pump Body ................................................................................................................................. 14 - 18 Nm (10 - 13 ft. lbs.)
Flow Control Valve Connector To:
Pump Body ............................................................................................................................................................... 40 - 60 Nm (30 - 44 ft. lbs.)
Seat Belt Replacement

Seat Belt Replacement
Front Seat Belts Lower Anchor Bolt 25.4-32.0 ft.lb
Upper Anchor Mounting Bolt 3.5-4.5 ft.lb
Retractor Mounting Bolt 3.5-4.5 ft.lb
Seat Belt Height Adjusting Mounting Bolt 3.5-4.5 ft.lb
Rear Seat Belts Lower Anchor Bolt 4.0-5.5 ft.lb
Upper Anchor Mounting Bolt 4.0-5.5 ft.lb
Center Belt W/ Buckle Attaching Bolts 4.0-5.5 ft.lb
Spare Tire
Temporary Spare Tire:
Wheel Size ................................................................................................................................................................................................ 4T x 15
Tire Size .......................................................................................................................................................................................... T125/70 D 15
Plug Gap 1.0 - 1.1 mm (0.039 - 0.043 in.)
Tightening Torque 20 - 30 Nm (15 - 21 lb-ft.)

Starter Motor
Starter Motor To Transaxle ................................................................................................................................................. 22 - 32 Nm (16 - 23 ft. lbs.)
Steering Column
Steering Column:
Member Mounting Bolt .................................................................................................................................................. 15 - 20 Nm (11 - 14 ft. lbs.)
To Column Member Mounting:
Upper ....................................................................................................................................................................... 13 - 18 Nm (9.4 - 13 ft. lbs.)
Lower ........................................................................................................................................................................ 8 - 13 Nm (5.8 - 9.4 ft. lbs.)
Member To Cowl Panel ................................................................................................................................................... 9 - 14 Nm (6.5 - 10 ft. lbs.)
Joint Assembly .................................................................................................................................................................... 15 - 20 Nm (11 - 14 ft. lbs.)
Steering Gear
Gear Box:
Steering Gear Type .......................................................................................................................................................... Power Rack and Pinion
Steering Gear Ratio ...................................................................................................................................................................................... 48.39
Pinion Gear Number Of Teeth ............................................................................................................................................................................ 7
Rack Stroke .............................................................................................................................................................................................. 150 mm
Pinion Turning Torque (Loosen Rack Support Plug Approximately 10°):
Standard Value ................................................................................................................................................ 0.6 - 1.3 Nm (0.4 - 0.9 ft. lbs.)
Pressure Hose To Gear Box ........................................................................................................................................... 12 - 18 Nm (8.7 - 13 ft. lbs.)
Return Tube To Gear Box ............................................................................................................................................. 12 - 18 Nm (8.7 - 13 ft. lbs.)
Tie Rod To Rack:
MANDO ................................................................................................................................................................. 80 - 100 Nm (58 - 72 ft. lbs.)
Rack Support Plug Lock Nut:
MANDO ................................................................................................................................................................... 50 - 70 Nm (36 - 51 ft. lbs.)
Pinion and Valve Assembly to Self Locking Nut:
MANDO ................................................................................................................................................................... 20 - 30 Nm (14 - 22 ft. lbs.)
End Plug .......................................................................................................................................................................... 50 - 70 Nm (36 - 51 ft. lbs.)
Feed Tubes ..................................................................................................................................................................... 12 - 18 Nm (8.7 - 13 ft. lbs.)
Mounting Bracket To Crossmember ............................................................................................................................... 60 - 80 Nm (43 - 58 ft. lbs.)
Steering Knuckle
Knuckle To Strut Assembly ............................................................................................................................................... 90 - 105 Nm (65 - 75 ft. lbs.)
Steering Wheel
Steering Wheel Free Play .............................................................................................................................................................. 30 mm (1.18 inch)
Steering Effort:
Standard ........................................................................................................................................................................... 30 N (3.0 kg, 6.74 lbs.)
Steering Wheel Lock Nut ............................................................................................................................................... 40 - 50 Nm (29 - 36 ft. lbs.)
Service Specifications
Type ........................................................................................................................................................ Hydraulic Cylindrical Double-Acting Type
Maximum Length .................................................................................................................................................... 510 ± 3 mm (19.96 - 20.19 inch)
Compressed Length ................................................................................................................................................. 356 ± 3 mm (13.89 - 14.13 inch)
Stroke ........................................................................................................................................................................................... 154 mm (6.06 inch)
Temperature Sensor (Gauge)

Engine Coolant Temperature Sender ...................................................................................................................................... 10 - 12 Nm (7 - 9 ft. lbs.)
Throttle Body
Throttle Body Stay .............................................................................................................................................................. 15 - 22 Nm (11 - 16 ft. lbs.)
Throttle Body To Intake Manifold ...................................................................................................................................... 15 - 22 Nm (11 - 16 ft. lbs.)
Throttle Cable/Linkage
Accelerator Cable Adjusting Bolt ............................................................................................................................................... 4 - 6 Nm (3 - 4 ft. lbs.)
Accelerator Cable Bolts To:
Intake Manifold ....................................................................................................................................................................... 4 - 6 Nm (3 - 4 ft. lbs.)
Mouting Screws 1.5-2.5 Nm
Tie Rod End Ball Joint:
Starting Torque ...................................................................................................................................................... 0.5 - 2.5 Nm (3.6 - 18 ft. lbs.)
Tie Rod Free Length (From End Of Rack Boot To Locking Nut):
Standard Value ................................................................................................................................................ 204.6 ± 1 mm (8.055 ± 0.04 inch)
Tie Rod To Rack:
MANDO ................................................................................................................................................................. 80 - 100 Nm (58 - 72 ft. lbs.)
Tie Rod End Lock Nut .................................................................................................................................................... 50 - 55 Nm (36 - 40 ft. lbs.)
Tie Rod End To Knuckle ................................................................................................................................................ 24 - 34 Nm (17 - 25 ft. lbs.)
Tie Rod End

Tie Rod End To Knuckle .................................................................................................................................................... 24 - 34 Nm (17 - 25 ft. lbs.)
Vehicle Speed Sensor

Speedometer Sensor ............................................................................................................................................................... 1 - 2 Nm (0.7 - 1.3 ft. lbs.)
Wheel Bearing
Wheel Bearing:
Type ......................................................................................................................................................... Double Row Angular Contact Ball Bearing
Dimension (O.D. x I.D.) ............................................................................................................................................................. 80 x 40 (3.15 x 1.57)
Starting Torque ......................................................................................................................................................................... 1.9 Nm (16 inch lbs.)
Wheel Fastener
Tighten the nuts for the steel and aluminum alloy wheel to a specification of 90-110 Nm (65-80 ft. lbs.).
Tighten in the following order: Go around the wheel tightening every other nut until they are all tight. Then double-check each nut for tightness.
Hub Bearing Starting Torque:
Limit ...................................................................................................................................................................... 1.3 Nm (11 inch lbs.) Or Less
Hub Bearing Axial Play:
Limit .................................................................................................................................................................... 0.11 mm (0.0043 inch) Or Less
Axle Nut Driveshaft Nut 200 - 260 Nm
Rear Axle Carrier Stud Bolt 200 - 260 Nm
Wheels
Wheel Type ......................................................................................................................................................................................................... Steel
Wheel Size ........................................................................................................................................................................................... 5.5 JJ x 14
Tire Size ............................................................................................................................................................................................ P195/70R14
Wheel Type ................................................................................................................................................................................................ Aluminum
Wheel Size .............................................................................................................................................................................................. 6 JJ x 15
Tire Size ............................................................................................................................................................................................ P205/60R15
Compression Check
Cylinder compression at 250 - 400 rpm ...................................................................................................................... 1.18 kPa (12.0 kg/cm2,171 psi)
Pressure differential between cylinders .......................................................................................................................... 100 kPa (1.0 kg/cm2, 14 psi)
Engine Oil Pressure

Engine Oil Pressure
Engine Oil Pressure 80 kPa (11.4 psi) or more

With oil temperature at 75 - 90 deg. C (167 - 194 deg. F)
Fuel Pressure
Fuel Pressure Specifications
With fuel pressure regulator vacuum hose disconnected ............................................................................................... 320 - 340 Kpa ( 46 - 49 psi )
With fuel pressure regulator vacuum hose connected ................................................................................................................... 270 Kpa ( 39 psi )
Vacuum Hose Connected 270 kPa
Disconnected 330-350 kPa
Fuel Pump
Fuel Pressure Specifications
With fuel pressure regulator vacuum hose disconnected ............................................................................................... 320 - 340 Kpa ( 46 - 49 psi )
With fuel pressure regulator vacuum hose connected ................................................................................................................... 270 Kpa ( 39 psi )
Oil Pump, Engine
Oil Pressure At Curb Idle Speed:
Oil Temperature 75 - 90°C (167 - 194°F) ......................................................................................................................... 80 kPa (11.4 psi) Or More
Power Steering Pump

Oil Pump:
Relief Pressure .......................................................................................................................................... 7.36 - 8.04 MPa (1066.5 - 1166.0 psi)
*Fluid Pressure With Gauge Hose Valve Closed:
............................................................................................................................................................................................... 7.85 kPa (1138 psi)
*Be Sure Not To Keep The Shut-Off Valve On The Pressure Gauge Closed For Longer Than Ten Seconds.
Radiator Cap
Main Valve Opening Pressure ................................................................................................................................ 81.4 - 107.8 kPa (11.80 - 15.64 psi)
Main Valve Closing Pressure ............................................................................................................................................................ 68.6 kPa (9.95 psi)
Vacuum Valve Opening Pressure ................................................................................................................................................... -686 kPa (-1.00 psi)
Thermostat
Thermostat
Normal Opening Temperature 88 deg. C (190 deg. F)
Opening Temperature Range 86.5 - 89.5 deg, C (187.7 - 193.1 F)
Wide Open Temperature 100 deg. C (212 deg.F)
Tire Inflation Pressure:
Steel Wheel ....................................................................................................................................................................................... 207 kPa (30 psi)
Aluminum Wheel .............................................................................................................................................................................. 207 kPa (30 psi)
Spare Tire
Temporary Spare Tire ....................................................................................................................................................................... 414 kPa (60 psi)
SPECIFIED LUBRICANTS
Capacity .......................................................................................................................................................................... 6.1 liters (6.4 US quarts)
Fluid - A/T
SPECIFIED LUBRICANTS
Capacity .................................................................................................................................................................................... 6.1 liters (6.4 US quarts)
Constant Velocity Joint Boot

Birfield Joint Boot Grease:
L.H.
................................................................................................................................................................ In The Joint 55 ± 3g (1.92 ± 0.1 oz.)
................................................................................................................................................................ In The Boot 55 ± 3g (1.93 ± 0.1 oz.)
R.H.
.................................................................................................................................................................. In The Joint 60 ± 3g (2.1 ± 0.1 oz.)
................................................................................................................................................................ In The Boot 55 ± 3g (1.93 ± 0.1 oz.)
Double Offset Joint Boot Grease:
(L.H. and R.H.)
.................................................................................................................................................... In the joint 60 ± 3g (2.1 ± 3g (2.1 ± 0.1 oz.)
.................................................................................................................................................................... In the boot 40 ± 3g (1.4 ± 0.1 oz.)
Cooling System:
Quantity ................................................................................................................................................................................... 7.3 liters (7.7 US Qts.)
Coolant
Coolant
Coolant Capacity 7.3 Liters (7.7 U.S. qts., 6.4 Imp. qts.)
Engine Oil
The manufacturer's Shop Repair Manual gives two different capacities for the Sonata model. However,they are the same for both engines.
Per the "Recommended Lubricants and Capacities" section:

Specified amount:
Oil pan ........................................................................................................................................................................................... 3.0 Liters (3.17 Qts.)
Oil filter ............................................................................................................................................................................................ 0.3 Liter (0.32 Qt.)
Total ............................................................................................................................................................................................... 3.3 Liters (3.47 Qts.)
Per the "Engine Lubrication" section in both of the "Engine Mechanical" sections
Specified amount:
Oil pan ............................................................................................................................................................................................. 3.7 Liters (3.9 Qts.)
Oil filter ............................................................................................................................................................................................ 0.3 Liter (0.32 Qt.)
Total ................................................................................................................................................................................................. 4.0 Liters (4.2 Qts.)
NOTE: It is recommended that the oil be refilled with 3.0 Liters (3.17 Qts.) and the engine run and then shut off. Check dipstick for fluid level and a
Refrigerant and oil capacity specifications are located under Refrigerant and Refrigerant Oil.
See: Heating and Air Conditioning/Refrigerant Oil
See: Heating and Air Conditioning/Refrigerant
R-134a Capacity 725 +/- 25 g (1.6 lbs)
Total System 210-230 cc (12.8 - 14 oz.)
USA Import
Evaporator 50 cc (1.6 oz) 1.8 oz
Condenser 30 cc (1.0 oz) 1.1 oz
Accumulator 80 cc (2.6 oz) 2.9 oz
Transaxle Oil
Transaxle Oil
Transaxle Oil Capacity: 2.2 liters (2.3 U.S. qts., 1.94 Imp. qts.)
Fluid - M/T
Transaxle Oil ............................................................................................................................................................................... 2.5 liters (2.6 US Qts.)
Power Steering Fluid

Specified amount .............................................................................................................................................................................. 0.9 Liter (0.95 Qt.)
Power Steering Pump

Power Steering Fluid ................................................................................................................................................................... 0.9 liters (0.95 Quarts)
ATF Type ................................................................................................................................................................... Hyundai SP-II, Mopar ATF 7176.
Note: The maintenance interval for ATF and filter has been changed from the initial factory recommendation. Refer to TSB# 98-40-010 (dated Sept
Fluid - A/T
ATF Type .................................................................................................................................................................. Hyundain SP-II, Mopar ATF 7176
Backing Plate
Parking Brake Shoe And:
Backing Plate Contact Surfaces ................................................................................................................................ Bearing Grease, NLGI No.0 - 1
Brake Fluid
Brake Fluid .................................................................................................................................................................................... DOT3 Or Equivalent
Brake Pedal Assy

Brake Pedal Bushing and:
Brake Pedal Bolt ............................................................................................................................................ Chassis Grease SAE J310, NLGI No.0
Clevis Pin ............................................................................................................................................... Wheel Bearing Grease SAE J310, NLGI No.2
Brake Shoe
Shoe, Backing Plate and Anchor Plate:
Contact Surfaces ................................................................................................................................... Multipurpose Grease SAE J310, NLGI No.2
Clutch Disc, M/T

Inner Surface Of Clutch Disc Spline .............................................................................................................................................. Molywhite TA No. 2
Specified Fluid SAE J1703 DOT 3 Brake Fluid

Inner Surface Of Clutch Master Cylinder And Outer Circumference Of:
Piston Assembly ............................................................................................................................................................................. Brake fluid DOT 3
Clutch Master Cylinder Push Rod, Clevis Pin And:
Washer ............................................................................................................................................... Wheel Bearing Grease SAE J310, NLGI No. 2
Clutch Pedal Assembly

Clutch Pedal Shaft And Bushings ...................................................................................................................... Chassis grease SAE J310, NLGI No. 1
Clutch Release Bearing, M/T

Contact Surface Of Release Bearing And Fulcrum Of:
Clutch Release Fork .............................................................................................................................................................. Molywhite TA No. 2
Inner Surface Of Clutch Release Bearing ................................................................................................................................... Molywhite TA No. 2
Clutch Release Fork, M/T

Contact Portion Of Release Fork To Release Cylinder:
Push Rod ............................................................................................................................................................................... Molywhite TA No. 2
Clutch Slave Cylinder

Inner Surface Of Clutch Release Cylinder And Outer Circumference Of:
Piston And Cup ........................................................................................................................................................................ Brake fluid DOT 3
Constant Velocity Joint Boot

Birfield Joint Boot Grease ....................................................................................................................................................... Centoplex 278M/136K
Double Offset Joint Boot Grease ............................................................................................................................................... Amblygon TA 10/2A
Fluid Type
Fluid Type
Coolant Type Ethylene Glycol Antifreeze/Coolant
Concentration 30 to 60 percent
Engine Oil
Specified type .............................................................................................................................................................. API classification SG or SG/CD
Specified viscosities at ambient temperature ranges:

Above 0°C (32°F) ................................................................................................................................ SAE 10W - 40, 10W - 50, 20W - 40, 20W - 50
Between 0°C (32°F) and -23°C (-10°F) .................................................................................................................................................. SAE 10W - 30
Between 0°C (32°F) and 38°C (99°F) ....................................................................................................................................................... SAE 5W - 40
Below 0°C (32°F) ...................................................................................................................................................................................... SAE 5W - 30
NOTE: Lubricants which do not have both a SAE grade number and an API service classification on the container should not be used.
Refrigerant and oil type specifications are located under Refrigerant and Refrigerant Oil.
See: Heating and Air Conditioning/Refrigerant Oil
See: Heating and Air Conditioning/Refrigerant
Refrigerant R-134a
(PAG) Poly Alkylene Glycol Oil FD46XG or Equivalent
Specified type ............................................................................................................................................... API classification GL-4, SAE 75W / 85W
Case, M/T
Transaxle Case and Clutch Housing Alignment Surface .............................................................................................................. THREE BOND 1216
Transaxle Case and Rear Cover Alignment Surface ..................................................................................................................... THREE BOND 1216
Fluid - M/T
API classification .................................................................................................................................................................................................... GL-4
Viscosity ................................................................................................................................................................................................ SAE 75W-85W
Input Shaft, M/T
Input Shaft Spline ........................................................................................................................................................................... Molywhite TA No. 2
Transaxle Input Shaft Oil Seal Lip:
................................................................................................................. Retinax AM, Molytex Grease EP 2, Mobil Grease Special, Gulflex Moly
Shifter M/T
Shift Lever Bushing ................................................................................................................................. Multipurpose Grease SAE J310, NLGI No.2
Parking Brake System

Parking Brake Shoe And:
Backing Plate Contact Surfaces ................................................................................................................................ Bearing Grease, NLGI No.0 - 1
Fluid Type PSF-3
Power Steering Pump

Oil Pump ................................................................................................................................................................................... ATF DEXRON II Type
Steering Column
Steering Column Bearing ....................................................................................................................... Multipurpose Grease SAE J310a, NLGI No.2
Steering Gear
Steering Gear Box Rack, Pinion Gear Part:
............................................................................................................................................................ Multipurpose Grease SAE J310a, NLGI No.2
Bellows ................................................................................................................................................................................................... Silicone Grease
Suspension Strut
In Insulator Bearing Of Strut:
........................................................................................................................................... SAE J310a, Chassis Grease (NLGI No.0 Or Equivalent)
Wheel Bearing Lubricant

Wheel Bearing Lubricant
Lubricant SAE J310a multi-purpose grease NLGI or equivalent

Vehicle: Locations
A - Z Component List
CKP - CRANKSHAFT POSITION SENSOR & CMP - CAMSHAFT POSITION SENSOR CONNECTORS
Dash Fuse Box
Fuse Box Layout

Fuse Index
Engine Compartment Relay and Fuse Box
Relay Box And Fuse Box Layout

Fuse And Relay Information

C01-4, C01-5, C1-06, C1-07 (ECM)
C02, C03 (Cooling Control Module)

C08, C09 (A/C Low Pressure Switch)
C12 (A/C Compressor)
C17 - C18
C21 ~ C23
C25
C26
C28
C33, C34, C35 (Thermo Sensor)

C37
C38
C40-1, C40-2 (TCM)

C51-4, C51-5, C51-6, C51-7
C52 - C53
C54
C60, C62, C63
C64 (A/C Low Pressure Switch)

C67 Brake fluid level Sensor, C69
C72
C73
C74
C81-1, C81-2 (TCM)


C89, C90 Generator, C91

D03, D04, D23, D24
D06
D07, D08, D27, D28

D15 - D35
D17 - D37
EC01, EC02
EC04
EI01
EM01 To EM04
E02 Right Front Wheel Sensor
E04 ABS Modulator
E05, E06 ABS Relay, E06-1 ABS pump Motor
E07 (A/C Relay) through E14

E27, E28 Generator, E30

E34
E36
E46 Left Front Wheel Sensor

E54 (Ambient Temperature Sensor)
I01 - I22
I02, I03 (Blower Motor), I04, I05 (Blower Relay)
I06 (Fresh/Recirc Switch/Control Panel Illumination), I07, I11
I16-1 To I16-3
I22
I25 (High Blower Relay)
I26 (In-car Temperature Sensor)
I27 (A/C Control Module)
I28 (Blend Door Actuator)

I29 (Power Transistor)
I30 (Photo Sensor)
MC01 - MC02, TCM
MD03 - MD04
MI01, MI02, MI03

M14 Stop Lamp Switch
M17 To M24 ABS Module, M25 To M29, M22 Flasher Unit
M27 (Intermittent Wiper Timer)

M39 Parking Brake Switch To M41

M44 - M57
M45 - M45-1
M47 - M48
M50 Right Rear Wheel Sensor, M53
M58 Power Antenna, M59 Left Rear Wheel Sensor

R07 - R08
G02 - G08
G03, G04
G09
G13, G16
Control Harness
Harness Layout
C01-4 ECM
C01-5 ECM
C01-6 ECM
C01-7 ECM
C02 Engine control relay
C03 Cooling control module
C04 Pre-excitation resistor
C05 EGR temperature solenoid
C07 Front oxygen sensor (Except California area)
C07-1 Front oxygen sensor (California area)
C08 A/C pressure switch (Low)
C09 Wiper motor
C10 Ignition power transistor
C11 Ignition coil
C12 A/C compressor
C15-1 Injector #1
C15-2 Injector #2
C15-3 Injector #3
C15-4 Injector #4
C16 Throttle position sensor
C17 Brake fluid level sensor
C18 Cruise control actuator
C19 Fuel pump checker
C20 Ignition control adjusting connector
C21 Kick down servo switch
C22 Oil temperature sensor
C23 Pulse generator
C24 Crankshaft position sensor
C25 Back up lamp switch
C26 Volume air flow sensor
C27 Transaxle range switch
C28 Transaxle valve body
C29 Vehicle speed sensor
C32 Idle speed control motor
C33 Thermo sensor (115 °C)
C34 Engine coolant temperature sender
C35 Engine coolant temperature sensor
C37 Camshaft position sensor
C38 Manifold differential pressure sensor
C39 Purge solenoid (Except California area)
C39-1 Purge solenoid (California area)
C40-1 TCM
C40-2 TCM
C43 Rear oxygen sensor (California area)
EC01 Connection with ENGINE harness
ECM GROUND G11
TCM GROUND G12
Dash GROUND G13
MC01 Connection with MAIN harness
Door Harness (Front)
Harness Layout
D02 Door key hole ILL. lamp

D03 Left tweeter speaker
D23 Right tweeter speaker
D04 Left outside mirror motor & Defogger
D24 Right outside mirror motor & Defogger
D06 Right front power window switch
D07 Left front power window motor
D27 Right front power window motor
D08 Left door speaker
D28 Right door speaker
D09 Power window main switch
D10 Power door mirror switch
D11 Trunk lid opener switch
D12 Left front door lock actuator
D32 Right front door lock actuator
D13 Left door lamp
D33 Right door lamp
MD01 Connection with RIGHT MAIN harness
MD03 Connection with LEFT MAIN harness
Door Harness (Rear)

Harness Layout
D15 Left rear power window switch

D35 Right rear power window switch
D16 Left rear power window motor
D36 Right rear power window motor
D17 Left rear door lock actuator
D37 Right rear door lock actuator
MD05 Connection with RIGHT MAIN harness
Engine Harness
Harness Layout
E02 Right front wheel sensor

E03 Start solenoid extension
E03-1 Start solenoid
E04 ABS modulator
E05 ABS relay box
E06 ABS relay box
E06-1 ABS motor pump
E07 A/C relay
E08 Tail lamp relay
E09 Head lamp relay 1
E10 Head lamp relay 2
E11 Radiator fan relay (Low)
E12 Radiator fan relay (High)
E13 Condenser fan relay(Low)
E14 Condenser fan relay (High)
E16 Right head lamp
E17 Right horn
E22 Radiator fan motor
E25 Center horn
E26 Radiator resistor
E27 Generator (B+)
E28 Generator (L, S)
E29 Power steering switch
E30 Oil pressure switch
E31 Condenser resistor
E32 Condenser fan motor
E33 A/C pressure switch (High)
E36 Battery terminal
E40 Left head lamp
E42 Wind Shield washer motor
E44 DRL control module
E46 Left front wheel sensor
E47 Left turn signal lamp
E48 Right turn signal lamp
E49 Left front fog lamp
E50 Right front fog lamp
E52 DRL relay
E53 Start relay
E54 Ambient temperature sensor
E60 DRL resistor (CANADA)
EC01 Connection with CONTROL harness
EI01 Connection with INSTRUMENT harness
EM01 Connection with MAIN harness
G09 Right fender ground
G10 Left fender ground
Instrument Harness
Harness Layout
I01 Right front speaker

I02 Thermostatic switch
I03 Blower motor
I04 Blower resistor (Manual A/C)
I05 Blower relay
I06 Fresh/Recirc switch & Heater control panel ILL. (Manual A/C)
I07 Blower switch
I10 Hazard switch
I11 A/C switch (Manual A/C)
I12 Digital clock
I13 Defogger switch
I14 Rheostat
I16-1 Instrument cluster
I18 Cruise control switch
I22 Left front speaker
I23 Front fog lamp switch (CANADA)
I24 Front fog lamp switch (USA)
I25 High Blower relay (Auto A/C)
I26 In car sensor (Auto A/C)
I27 A/C control module (Auto A/C)
I28 Blend door actuator (Auto A/C)
I29 Power transistor range (Auto A/C)
I30 Photo sensor (Auto A/C)
EI01 Connection with ENGINE harness
MI01 Connection with MAIN harness
Main Harness (Roof)

Harness Layout
M87 Map lamp

M88 Right vanity lamp
M89 Room lamp
M91 Over head console lamp
M92 Left Sunroof relay
M93 Sunroof motor
M94 Right Sunroof relay
MM02 Connection with MAIN harness
MM03 Connection with SUNROOF harness
Main Wiring Harness

Harness Layout
M02 Multifunction switch

M05 Ignition key lock solenoid (A/T)
M06 Door warning & IG key ILL. switch (ETACM)
M07 Ignition switch
M09 Audio
M10 Shift and key lock control module
M11-1 ETACM
M11-2 ETACM
M12 Cigarette lighter
M13 Cruise control module
M13-1 Cruise control module extension
M14 Stop lamp switch
M15 Starter clutch pedal position switch (M/T)
M16 Cruise clutch pedal position switch (M/T)
M17 Power window relay
M19 Horn relay
M20 Fog lamp relay
M22 Flasher unit
M23 Wiper motor relay (ETACM)
M24 ABS control module
M25 Power door lock relay (ETACM)
M26 Seat belt timer (Without ETACM)
M27 Intermittent wiper timer (Without ETACM)
M28 Chime bell
M31 Data link connector
M52 Defogger relay (ETACM)
M69 Audio remote control switch (ETACM)
M70 Slip ring connector (Without air bag)
M71 Left audio remote control switch (Without air bag)
M72 Right audio remote control switch (Without air bag)
M73 Horn switch (Without air bag)
M74 Slip ring connector (Air bag)
M75 Left audio remote control switch (Air bag)
M76 Right audio remote control switch (Air bag)
M77 Horn switch (Air bag)
M82 Contact coil (Air bag)
M83 SRS control module (Air bag)
M84 Passenger air bag
EM01 Connection with ENGINE harness
MC01 Connection with CONTROL harness
MD01 Connection with RH FRONT DOOR harness
MD03 Connection with LH FRONT DOOR harness
MD04 Connection with LH FRONT DOOR harness
M101 Connection with INSTRUMENT harness
MM01 Connection with AIR BAG harness
MM02 Connection with ROOF harness
G01 Deck ground
G02 Control support panel ground
G03 ABS ground
G04 Deck ground
G08 Air bag ground
M33 Seat belt switch
M34 Left front seat warmer
M36 Left front seat warmer switch
M37 Power/Normal switch (Air)
M38 Rear oxygen sensor (Except California area)
M39 Parking brake switch
M40 Right front seat warmer switch
M40-1 Slide adjuster
M40-2 Slide adjuster limit switch
M40-3 Front height adjuster
M40-4 Rear height adjuster
M40-5 Reclining adjuster
M40-6 Power seat adjuster switch
M41 Air shift lever
M42 Right front seat warmer
M43 Right front door switch
M44 Right rear door switch
M45 Rear window defogger (+)
M45-1 Rear window defogger (-)
M46 Right rear speaker
M47 High mounted stop lamp
M48 Trunk room lamp
M49 Left rear speaker
M50 Right rear wheel sensor
M53 Defogger timer (Without ETACM)
M54 Left front door switch
M55 Fuel pump sensor
M56 Fuel pump motor
M57 Left rear door switch
M58 Power antenna
M59 Left rear wheel sensor
M60 Key interlock switch (Air)
M62 Canister close valve (CCV)
M63 Fuel tank pressure sensor
MD05 Connection with RH REAR DOOR harness
MD06 Connection with LH REAR DOOR harness
MM04 Connection with POWER SEAT harness
MR01 Connection with TRUNK LID harness
MR02 Connection with TRUNK ROOM harness
G05 Console ground
G06 Rear ground
G07 Rear ground
G22 Rear window defogger ground
Trunk Room and Trunk Lid Harness
Harness Layout
R01 Left rear combination lamp

R02 Trunk room lamp switch
R03 Right rear combination lamp
R06 Trunk lid solenoid
R07 Right license lamp
R08 Left license lamp
MR01 Connection with MAIN harness
MR02 Connection with MAIN harness
G21 Trunk room ground
Vehicle: Diagrams
Connector Configurations
Connector Configuration
This shows the cavity or terminal locations in all the multi-pin connectors shown in the schematic diagrams. It is helpful for you to locate check
points, together with the wire colors and terminal numbers in the schematic. The configuration drawings shows the connector views as seen from a
component after the harness connector has been disconnected. When more than one connector is connected to a component, the connectors are all
shown together. Both halves of in-line connectors are shown together.
Connector Identification
A connector identification symbol consists of a wiring harness location classification symbol corresponding to each other wiring harness location
and number peculiar to the connector.
These connector locations can be found in the HARNESS LAYOUT.
NOTE: Connectors which connect each wiring harness are represented by symbols.
Connector View and Numbering Order

Connector View
CONNECTOR VIEW
Numbering Order
NUMBERING ORDER
Harness Layouts
Harness Layout
Electrical wiring connectors are classified according to the wiring parts in the harness layouts.
Key to Wiring Diagrams and Symbol I.D.
The symbols and the abbreviations explained here are used throughout the database.
Symbols (Part 1 Of 3)
Symbols (Part 3 Of 3)
Schematic Diagrams
The starting point of each system section is the electrical diagram, these diagrams show how all the components work together, such as electrical
current paths from power source to ground (via electrical load), switch connections at each positions, and other related circuit functions.
It is important to fully understand how a circuit work prior to troubleshooting and diagnosis.
Splice Identification
A splice identification symbol consists of a wiring harness location classification symbol corresponding to each wiring harness location and number
peculiar to the splice. These splice locations can be found in the HARNESS LAYOUTS.
Wire Color Abbreviations

The following abbreviations are used to identify wire colors in the circuit schematics.
B ............................................................................................................................................................................................................................. Black
L .............................................................................................................................................................................................................................. Blue
Br ......................................................................................................................................................................................................................... Brown
G ............................................................................................................................................................................................................................ Green
Gr ............................................................................................................................................................................................................................ Gray
Lg ................................................................................................................................................................................................................. Light Green
O .......................................................................................................................................................................................................................... Orange
P ............................................................................................................................................................................................................................... Pink
R ............................................................................................................................................................................................................................... Red
W ........................................................................................................................................................................................................................... White
Y .......................................................................................................................................................................................................................... Yellow
Li .................................................................................................................................................................................................................... Light Blue
Continuity and Voltage Test
1. Disconnect the battery negative terminal.

2. Connect one lead of a self powered test lamp or ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero Ohms.
3. Connect the other lead to the other end.
4. If the self-powered test lamp glows, there is continuity. If you are using an ohmmeter, low or zero resistance means good continuity.
Jumper Wire With Fuse
Use a jumper wire with fuse to by pass an open circuit.

A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is available with small clamp connectors providing
adoption to most of the connectors without damage.
CAUTION
Do not use a fuse with a higher rating than the specified fuse that protests the circuit being tested. Do not use this tool in any situation to substitute
for input or output at the solid-state control module, such as ECM, TCM, etc.
Self-Powered Test Lamp and Ohmmeter
Use a self powered test lamp or a ohmmeter to check for continuity. Self-powered test lamp is made of a bulb, battery and two leads are touched
together, the lamp will go on. Prior to checking the points, first disconnect the battery ground cable or remove the fuse which feeds the circuit you
are working on.
CAUTION:
Never use a self-powered test lamp on circuits that contain solid state modules. Damage to these units may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much resistance there is between two points along a
circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with at 10 Mega Ohm or higher impedance digital multimeter. When
measuring resistance with a digital multimeter, battery negative terminal should be disconnected. Otherwise, there may be incorrect readings.
Diodes and solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a component is affecting a measurement, take
one reading, reverse the leads and take a second reading. If the readings differ, the solid-state device is affecting the measurement.
Testing For Short to Ground
1. Disconnect the battery negative terminal.

2. Connect one lead of a self powered test lamp or an ohmmeter to the fuse terminal on the load side.
3. Connect the other lead to a ground.
4. Beginning near the fuse block move the harness from side to side. Continue this point (about six inches apart) while watching the self
powered test lamp or ohmmeter.
5. When the self powered test lamp glows, or ohmmeter registers, there is a short to a ground in the wiring near that point.
Testing For Short to Power
1. Remove the blown fuse. Leave the battery connected.

2. Connect the short finder across the fuse terminals.
3. Close all switches in series in the circuit you're testing.
4. Turn on the short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field around the wiring between the
fuse box and the short.
5. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each current pulse. Once you move the meter
past the point of the short, the needle will stop moving. Check around this area to locate the cause of the short circuit.
Testing For Voltage
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to separate the two halves of the connector. Instead,
probe the connector from the back. Always check both sides of the connector because dirt and corrosion between its contact surfaces can cause
electrical problems.
1. Connect one lead of a test lamp or voltmeter to a ground. If you are using a voltmeter, be sure it is the voltmeter's negative lead test you have
connected to ground.
2. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or terminal).
3. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the voltage reading. A loss of more than 1 volt from
specifications indicates a problem.
Troubleshooting Equipment
Short finder is available to locate short to a ground. The short finder creates a pulsing magnetic field in the shorted circuit and shows you the
location of the short through body trim or sheet metal.
Voltmeter and Test Lamp
Use a test lamp or a voltmeter on circuits without solid-state units and use a test lamp to check for voltage. A test lamp is made up of 12-Volt bulb
with a pair of leads attached. After grounding one lead, touch the other lead to various points along the circuit where voltage should be present.
When the bulb goes on, there is voltage at the point being tested.
CAUTION
A number of circuits include solid-state modules such as Engine Control Module (ECM) used with computer command control injection. Voltage
in these circuits should be tested only with a 10-Mega Ohm or higher impedance digital voltmeter. Never use a test lamp on circuits that contain
solid-state units. Damage to the units may result.
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is present or not, a voltmeter indicates how much
voltage is present.
Relay Box (E06, Harness Side)

ABSCM Connector (M60, ABSCM Harness Side Connector)

ABSCM Connector (M24, ABSCM Harness Side Connector)
(E04, Harness Side)
Ground Distribution
Ground Distribution (Part 1 Of 11)
Connector Configurations Are Found In The Diagram Section Of The Vehicle.

See: Connector Views
Connector Locations Are Found In The Locations Section Of Power And Ground Distribution.
See: Power and Ground Distribution/Locations
Power Distribution
Power Distribution (Part 1 Of 5)

Connector Locations Are Found In The Locations Section Of Power And Ground Distribution.
See: Power and Ground Distribution/Locations
Fuse Block
Connector Locations Are Found In The Locations Section Of The Fuse Block.
See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Locations
Air Bag Systems

Air Bag System (SRS)
Electrical Diagram
Connector Locations Are Found In The Locations Section Of The Air Bag System.
See: Restraint Systems/Air Bag Systems/Locations
Antilock Brakes / Traction Control Systems

Circuit Diagram
Anti-Lock Brake System (Part 1 Of 3)

Connector Locations Are Found In The Locations Section Of The Anti-Lock Brake System.
See: Brakes and Traction Control/Locations
Antitheft and Alarm Systems
Circuit Diagram
ETACS (Electronic Time & Alarm Control System) (Part 1 Of 4)




Connector Locations Are Found In The Locations Section Of The Antitheft and Alarm Systems.
See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Locations
Automatic Transmission/Transaxle
Shift And Key Lock Control System
Electrical Diagram
Connector Configurations Are Found In The Diagrams Of The Vehicle.

Connector Locations Are Found In The Locations Of The Shift and Key Lock Control System.
See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Locations
Backup Lamp
Backup Lamps
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Backup Lamp.
See: Lighting and Horns/Backup Lamp/Locations
Brake Lamp
Stop Lamps
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Stop Lamps.
See: Lighting and Horns/Brake Lamp/Locations
Brake Warning Indicator
Brake Warning System
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Brake Warning System.
See: Brakes and Traction Control/Brake Warning Indicator/Locations
Charging System
Charging System
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Charging System.
See: Starting and Charging/Charging System/Locations
Cooling System
Cooling System (Part 1 Of 2)

Cooling System (Part 2 Of 2)
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Cooling System.
See: Engine, Cooling and Exhaust/Cooling System/Locations
Courtesy Lamp
Courtesy And Trunk Lamps - With Sunroof
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Courtesy Lamp.
See: Lighting and Horns/Courtesy Lamp/Locations
Courtesy And Trunk Lamps - Without Sunroof
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Courtesy Lamp.
See: Lighting and Horns/Courtesy Lamp/Locations
Cruise Control
Cruise Control System (Part 1 Of 2)

Cruise Control System (Part 2 Of 2)
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Cruise Control.
See: Automatic Speed Control System/Locations
Daytime Running Lamp
Daytime Running Lights (Part 1 Of 3)

Connector Locations Are Found In The Locations Section Of The Daytime Running Lamp.
See: Lighting and Horns/Daytime Running Lamp/Locations
Canada
Front Fog Lamps (Canada)
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Fog Lamp.
See: Lighting and Horns/Fog/Driving Lamp/Locations
U.S.A
Front Fog Lamps (USA)
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Fog Lamp.
See: Lighting and Horns/Fog/Driving Lamp/Locations
Hazard Warning Lamps
Turn/Hazard Lamps (Part 1 Of 2)

Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Turn and Hazard Lamps.
See: Lighting and Horns/Hazard Warning Lamps/Locations
Headlamp
Head Lamps
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Head Lamp.
See: Lighting and Horns/Headlamp/Locations
Heated Glass Element
Rear Window Defogger System (Without ETACS)
Electrical Diagram

System Diagram
Connector Locations Are Found In The Locations Section Of The Heating and Air Conditioning System.
See: Heating and Air Conditioning/Locations
Electrical Diagrams
Blower And A/C Controls (Manual) (Part 1 Of 2)


Blower And A/C Controls (Automatic) (Part 1 Of 3)






Horn
Horns
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Horn.

See: Lighting and Horns/Horn/Locations
Schematics
Indicators (Part 1 Of 3)

Connector Locations Are Found In The Locations Section Of The Instrument Panel, Gauges and Warning Indicators.
See: Instrument Panel, Gauges and Warning Indicators/Locations
Illumination
Illuminations (Part 1 Of 5)

Indicators and Gauges
Gauges
Electrical Diagram

Cigarette Lighter
Cigarette Lighter
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Cigarette Lighter.
See: Instrument Panel, Gauges and Warning Indicators/Cigarette Lighter/Locations
Clock
Digital Clock
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Clock.

See: Instrument Panel, Gauges and Warning Indicators/Clock/Locations
Seat Belt Reminder Buzzer

Seat Belt Warning (Without ETACS)
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Seat Belt Warning Buzzer.
See: Instrument Panel, Gauges and Warning Indicators/Seat Belt Reminder Buzzer/Locations
License Plate Lamp
Tail, Parking And License Lamps (Part 1 Of 2)

Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The License Plate Lamp.
See: Lighting and Horns/License Plate Lamp/Locations
Mirrors
Power Door Mirrors
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Power Door Mirrors.
See: Body and Frame/Mirrors/Locations
Parking Lamp

Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Parking Lamp.
See: Lighting and Horns/Parking Lamp/Locations
Power Locks
Power Door Locks (Part 1 Of 2)

Power Door Locks (Part 2 Of 2)
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Power Locks.
See: Body and Frame/Locks/Power Locks/Locations
System Diagram
System Schematic
(California Area)
(Except California Area)
Wiring Diagram
Engine Control System (Part 1 Of 7)

Connector Locations Are Found In The Locations Section Of Powertrain Management.

See: Powertrain Management/Locations
Air Flow Meter/Sensor

Volume Air Flow Sensor
Circuit diagram
Data Link Connector
Data Link Details (Part 1 Of 2)

Data Link Details (Part 2 Of 2
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Data Link Connector.
See: Powertrain Management/Computers and Control Systems/Data Link Connector/Locations
Ignition System
Ignition System
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Ignition System.
See: Powertrain Management/Ignition System/Locations

Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Vehicle Speed Sensor.
See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Vehicle Speed
Sensor/Locations
Radio, Stereo, and Compact Disc
Sound System (Part 1 Of 3)

Connector Locations Are Found In The Locations Section Of The Amplifier, Sound Systems.
See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Locations
System Diagram
Power Seat
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Power Seat.
See: Body and Frame/Seats/Locations
Seat Heater
Seat Warmer
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Seat Warmer.
See: Body and Frame/Seats/Seat Heater/Locations
Starting System
Starting System
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Starting System.
See: Starting and Charging/Starting System/Locations
Sunroof / Moonroof
Sunroof
Electrical Diagram

Connector Locations Are Found In The Locations Section Of The Sunroof/Moonroof.

See: Body and Frame/Roof and Associated Components/Sunroof / Moonroof/Locations
Tail Lamp

Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Tail Lamp.
See: Lighting and Horns/Tail Lamp/Locations
Transmission Control Systems
Circuit Diagram
Automatic Transaxle Control System (Part 1 Of 3)


Connector Locations Are Found In The Locations Section Of The Automatic Transaxle Control System.
See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Locations
Trunk / Liftgate
Trunk Lid Opener
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Trunk/Liftgate.

See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Locations
With Sunroof
Courtesy And Trunk Lamps - With Sunroof
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Trunk Lamp.
See: Lighting and Horns/Trunk Lamp/Locations
Without Sunroof
Courtesy And Trunk Lamps - Without Sunroof
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Trunk Lamp.
See: Lighting and Horns/Trunk Lamp/Locations
Turn Signals

Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Turn and Hazard Lamps.
See: Lighting and Horns/Hazard Warning Lamps/Locations
Windows
Power Windows (Part 1 Of 3)

Connector Locations Are Found In The Locations Section Of Power Windows.

See: Windows and Glass/Windows/Locations
Wiper and Washer Systems
Intermittent Wiper And Washer (Without ETACS)
Electrical Diagrams

Connector Locations Are Found In The Locations Section Of The Intermittent Wiper and Washer System.
See: Wiper and Washer Systems/Locations
Automatic Transmission/Transaxle
NEUTRAL
PARKING
DRIVE (FIRST)
DRIVE (SECOND)
DRIVE (THIRD)
DRIVE (FOURTH)
LOCK UP
REVERSE
Computers and Control Systems: Testing and Inspection
Diagnostic Test Mode

DIAGNOSTIC TEST MODE
- When an abnormality is detected in one of the sensors or actuators related to emission control, the CHECK ENGINE/MALFUNCTION
INDICATOR LAMP illuminates as a warning to the driver.
- When an abnormality is detected in one of the sensors or actuators, a diagnostic trouble code corresponding to the abnormality is output.
- The RAM data inside the ECM that is related to the sensors and actuators can be read by means of the scan tool. In addition, the actuators can
be controlled under certain circumstances.
System Operation
ON-BOARD DIAGNOSTICS
- The recording condition of diagnostic trouble code After the ECM first detects a malfunction, a diagnostic trouble code is recorded when he
engine is restarted and the same malfunction is re-detected. (Malfunction is detected in driving cycle). However, for fuel system rich/lean
misfiring, a diagnostic trouble code is recorded on the first detection of the malfunction.
- The erasing condition of diagnostic trouble code. After recording the diagnostic trouble code, if the ECM does not re-detect the malfunction
for 40 driving cycles, the diagnostic trouble code will be erased from the ECM memory. However, for fuel system rich/lean or misfiring, the
diagnostic trouble code will be erased under the following conditions.
- When driving conditions (engine speed, engine coolant temperature, etc.) are similar to those when the malfunction was first recorded.
- When the ECM does not re-detect the malfunction for 80 driving cycles.
NOTE A "driving cycle" consists of engine start-up, vehicle operation beyond the beginning of closed loop operation.
How to Cope With Intermittent Malfunctions

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS
NOTE: Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the cause will be easier to find.
1. Ask the customer about the malfunction.

Ask what it feels like, what it sounds like, etc. Then ask about driving conditions, weather, frequency of occurrence, and so on.
2. Determine the conditions from the customer's responses
Typically, almost all intermittent malfunctions occur from conditions like vibration, temperature and/or moisture change, poor connections.
From the customer's replies, it should be reasoned which condition is influenced.
3. Use simulation test
In the cases of vibration or poor connections, use the simulation tests below to attempt to duplicate the customer's complaint. Determine the
most likely circuit(s) and perform the simulation tests on the connectors and parts of that circuit(s). Be sure to use the inspection procedures
provided for diagnostic trouble codes and trouble symptoms. For temperature and/or moisture conditions related intermittent malfunctions,
using common sense, try to change the conditions of the suspected circuit components, then use the simulation tests below.
4. Verify the intermittent malfunction is eliminated
Repair the malfunctioning part and try to duplicate the condition(s) again to verify the intermittent malfunction has been eliminated.
SIMULATION TESTS
For these simulation tests, shake, then gently bend, pull and twist the wiring of each of these examples to duplicate the intermittent
malfunction.
- Shake the connector up-and-down, and right-and-left.
- Shake the wiring harness up-and-down, and right-and-left.
- Vibrate the part or sensor.
With Generic Scan Tool

NOTE: This is the only information provided by the manufacturer for reading trouble codes for this system.
SELF-DIAGNOSIS
The ECM monitors the input/output signals (some signals at all times and the others under specified conditions). When the ECM detects an
irregularity, it memorizes the diagnostic trouble code, and outputs the signal to the self-diagnosis output terminal. The diagnosis results can be
read out Generic Scan Tool (GST). Diagnostic trouble code (DTC) will remain in the ECM as long as battery power is maintained. The
diagnostic trouble code will, however, be erased when the battery terminal or the engine control module (ECM) connector is disconnected or
erased by Generic Scan Tool.
CHECKING THE PROCEDURES (SELF-DIAGNOSIS)
NOTE:
1. When battery voltage is low, diagnostic trouble codes can not be read. Be sure to check the battery for voltage and charging system before
starting the test.
2. Diagnosis memory is erased if the battery or the ECM connector is disconnected. Do not disconnect the battery before the diagnostic trouble
codes are completely read and recorded.
Inspection Procedure (Using Generic Scan Tool)

1. Turn OFF the ignition switch.
2. Connect the scan tool to the data link connector on the lower crash pad.
3. Turn ON the ignition switch.
4. Use the Generic Scan Tool (GST) to check the diagnostic trouble code.
5. Repair the faulty part from the diagnosis chart.
6. Erase the diagnostic trouble code.
7. Disconnect the GST.
Without Scan Tool

An OBD-II scan tool must be used to read Diagnostic Trouble Codes (DTC's) from this vehicle.
With Generic Scan Tool
SELF-DIAGNOSIS
The ECM monitor the input/output signals (some signals at all times and the others under specified conditions). When the ECM detects that an
irregularity, it memorize the diagnostic trouble code, and outputs the signal to the self-diagnosis output terminal. The diagnosis results can be
read out Generic Scan Tool (GST). Diagnostic trouble code (DTC) will remain in the ECM as long as battery power is maintained. The
diagnostic trouble code will however, be erased when the battery terminal or the engine control module (ECM) connector is disconnected or
erased by Generic Scan Tool.
NOTE
(1) When battery voltage is low, diagnostic trouble codes can not be read. Be sure to check the battery for voltage and charging system before
starting the test.
(2) Diagnostic memory is erased if the battery or the ECM connector is disconnected. Do not disconnect the battery before the diagnostic trouble
codes are completely read and recorded.
Without Scan Tool

Diagnostic memory is erased if the battery or the ECM connector is disconnected. Do not disconnect the battery before the diagnostic trouble codes
are completely read and recorded.
Antilock Brake System (ABS)
DTC's 19 through 28
DTC's 31 through 41
DTC's 42 through 63
DTC's 64 through 77
Air Conditioning
1. A/C system is turned OFF during self diagnosis. The result of self diagnosis is displayed using 2 digits of the temperature display.
2. Diagnostic trouble codes are displayed during self diagnosis. However, after diagnosis is complete, relevant data is not stored in memory.
3. Self diagnosis of photo sensor is performed using a light bulb over 60W placed within 40cm with sun load applied.
NOTE: Without sun load, photo sensor error code displays.
4. Diagnostic trouble codes are as shown.
Failure safe function

1. Failure safe function will be accomplished, if the following compartments is open or short.
2. After correcting troubles, system will be work in normal condition.

Engine Controls
Part 1 of 4
Part 2 of 4
Part 3 of 4
Part 4 of 4
NOTE
(1) Do not replace the Engine Control Module (ECM) until a thorough terminal check reveals there are no short/open circuits.
(2) After the ECM detects a malfunction, a diagnostic trouble code is recorded when the engine is next started and the same malfunction is
re-detected. However, for items marked with a "*",the diagnostic trouble code is recorded on the first detection of the malfunction.
(3) 02 : Heated oxygen sensor
(4) Sensor 1 : Indicates sensors which are mounted closest to the engine.
(5) Sensor 2 : Indicates sensors which are mounted next closest to the engine.
Transaxle F4A33
DIAGNOSTIC TROUBLE CODES

FAIL-SAFE ITEM
If the fail-safe system is activated and the transaxle is locked in third gear, the diagnostic trouble code in the Fail-safe Code Description will be
stored in the RAM. Three of these fault codes can be stored.
The cancelation will occur if, with the transaxle locked in 3rd gear, the ignition key is turned to the OFF position, but the diagnostic trouble code
is stored in the RAM.
Transaxle KM175
DIAGNOSTIC TROUBLE CODES
FAIL-SAFE ITEMS
If the fail-safe system is activated and the transaxle is locked in third gear, the diagnostic trouble code in the Fail-Safe Code Description will be
stored in the RAM. Three of these fault codes can be stored.
All Other P Codes

If the P code is not listed, then:
- Either the code may not be valid for this vehicle or year.
- Or the information published by the OEM does not include this code for this vehicle or year.
- Or ALLDATA has not added information for this code yet.
P0100
DTC - P0100
Detection Condition
The Volume Air Flow (VAF) sensor is located in the air cleaner. The sensor measures the volume of air passing though the air intake and
generates a pulsed signal. The Engine Control Module (ECM) counts the pulses generated by the sensor and uses the signal to set fuel
injector base pulse width.
Part 1 of 2
Part 2 of 2
P0105
DTC - P0105
Detection Condition
The barometric pressure sensor is one of three sensors that make up the Volume Air Flow (VAF) sensor. The barometric pressure sensor is
essentially a strain gauge used to measure atmospheric pressure. Inside the sensor is a metal diaphragm with a small wire attached. The
diaphragm flexes according to changes in atmospheric pressure. When the diaphragm flexes, the wire attached to it stretches, changing the
resistance of the wire. The Engine Control Module (ECM) applies five volts to the barometric pressure sensor and measures the voltage drop
across the sensor. Sensor output is in volts and as atmospheric pressure decreases (higher altitudes), the voltage drop across the sensor
increases.
Part 1 of 2
Part 2 of 2
P0110
DTC - P0110
Detection Condition
The Intake Air Temperature (IAT) sensor is one of two sensors that work with the Volume Air Flow (VAF) sensor located in the air cleaner.
The IAT sensor is a variable resistor whose resistance changes as the temperature of the air flowing through the air intake changes. The
Engine Control Module (ECM) uses the IAT sensor input to adjust fuel injector pulse width. When the temperature sensed is cold, the ECM
enriches fuel mixture by increasing injector pulse width; as the air warms, the injector pulse width time is shortened.
Part 1 of 2
Part 2 of 2
P0115
DTC - P0115
Detection Condition
The Engine Coolant Temperature (ECT) sensor is located in the coolant passage of the cylinder head. The ECT sensor is a variable resistor
whose resistance changes as the temperature of the engine coolant flowing past the sensor changes. When coolant temperature is low, sensor
resistance is high; when coolant temperature is high, sensor resistance is low.
The Engine Control Module (ECM) checks ECT voltage fifty times per second and uses the information to adjust fuel injector pulse width
and ignition timing. When the temperature sensed is very cold, the ECM enriches the fuel mixture.
TROUBLESHOOTING
P0119
P0119 Engine Coolant Temperature Circuit-Intermittent.
NOTE: Hyundai Motor Corporation has not provided any diagnostic information for this DTC for this model year.
P0120
DTC - P0120
Detection Condition
The Throttle Position (TP) sensor mounts on the side of the throttle body and is connected to the throttle blade shaft. The TP sensor is a
variable resistor (potentiometer) whose resistance changes according to throttle blade shaft position. During acceleration, the TP sensor
resistance decreases; during deceleration, the TP sensor resistance increases. The TP sensor also includes an idle position switch. The switch
is closed in the idle position. The Engine Control Module (ECM) applies a reference voltage to the TP sensor and then measures the voltage
that is present on the TP sensor signal circuit. The ECM uses the TP sensor signal to adjust timing and injector pulse width. The TP sensor
signal along with the VAF sensor signal is used by the ECM to calculate engine load.
Part 1 of 2
Part 2 of 2
P0125
DTC - P0125
Detection Condition
To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three way catalytic converter is used, but for the
most efficient use of the three-way catalytic converter, the air ratio must be precisely controlled so that it is always close to the stoichiometric
air-fuel ratio.
The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This
characteristic is used to detect the oxygen concentration in the exact gas and provide feedback to the computer for control of the air-fuel ratio.
When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the
LEAN condition (small electromotive force: 0V).
When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exact gas is reduced and the oxygen
sensor informs the ECM of the RICH condition (large electromotive force: 1V)
The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection
time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to
perform accurate air-fuel ratio control.
The heated oxygen sensors include a heater which heats the Zirconia element. The heater is controlled by the ECM. When the intake air
volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration
detection.
TROUBLESHOOTING
P0130
DTC - P0130
Detection Condition
Part 1 of 3
Part 2 of 3
Part 3 of 3
P0135
DTC - P0135
Detection Condition
TROUBLESHOOTING
P0136
DTC - P0136
Detection Condition
Part 1 of 3
Part 2 of 3
Part 3 of 3
P0141
DTC - P0141
Detection Condition
"Fuel trim" refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short-term fuel trim and
long-term fuel trim. "Short term fuel trim" is the short-term fuel compensation used to maintain the air-fuel ratio at its ideal theoretical value.
The signal from the heated oxygen sensor indicates whether the air-fuel ratio is RICH or LEAN compared to the ideal theoretical value,
triggering a reduction in fuel volume if the air-fuel ratio is rich and an increase in fuel volume if it is lean. "Long-term fuel trim" is overall
fuel compensation carried out long-term to compensate for continual deviation of the short-term fuel trim from the central value due to
individual engine differences, wear over time and changes in the usage environment. If both the short-term fuel trim and long-term fuel trim
are LEAN or RICH beyond a certain value, it detected as a malfunction and the MIL lights up.
TROUBLESHOOTING
P0170
DTC - P0170
Detection Condition
"Fuel trim" refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short-term fuel trim and
long-term fuel trim. "Short term fuel trim" is the short-term fuel compensation used to maintain the air-fuel ratio at its ideal theoretical value.
The signal from the heated oxygen sensor indicates whether the air-fuel ratio is RICH or LEAN compared to the ideal theoretical value,
triggering a reduction in fuel volume if the air-fuel ratio is rich and an increase in fuel volume if it is lean. "Long-term fuel trim" is overall
fuel compensation carried out long-term to compensate for continual deviation of the short-term fuel trim from the central value due to
individual engine differences, wear over time and changes in the usage environment. If both the short-term fuel trim and long-term fuel trim
are LEAN or RICH beyond a certain value, it detected as a malfunction and the MIL lights up.
Part 1 of 2
Part 2 of 2
P0201
DTC - P0201, P0202, P0203, P0204, P0205, P0206

The fuel injectors are solenoid operated valves that are normally closed. When a fuel injector solenoid is energized (pulsed) the injector
needle valve moves, allowing pressurized fuel to pass through the injector and mix with air entering the engine. Each fuel injector (there is
one for each engine cylinder) is mounted in the intake manifold and is positioned to spray fuel into a cylinder head intake port.
The Engine Control Module (ECM) controls injector timing and pulse width (how long the fuel injectors are turned on). The ECM pulses the
fuel injectors based on information provided by its network of engine sensors. The ECM uses the crankshaft position sensor to determine
when to pulse the injectors. Engine coolant temperature, intake air temperature, air flow, barometric pressure and throttle position data are all
used by the ECM to calculate injector pulse width.
The ECM also uses its network of sensors to determine whether all injectors should be pulsed at the same time (simultaneous injection) or
each injector should be pulsed individually (sequential injection). Sequential injection is almost always used during normal engine operation,
simultaneous injection may be used when the engine is being cranked.
P0202
DTC - P0201, P0202, P0203, P0204, P0205, P0206

P0203
DTC - P0201, P0202, P0203, P0204, P0205, P0206

P0204
DTC - P0201, P0202, P0203, P0204, P0205, P0206

P0300
DTC - P0300
DESCRIPTION
With the ignition switch in ON or START, voltage is applied to the ignition coil. The ignition coil consists of two coils. High tension leads
go to each cylinder from the ignition coil. The ignition coil fires two spark plugs every power stroke (the cylinder under compression and the
cylinder on the exhaust stroke). Coil number one fires cylinders 1 and 4. Coil number two fires cylinders 2 and 3.
The ignition power transistor, controlled by the Engine Control Module (ECM), provides a switching circuit to ground for energizing the
primary ignition coils. When a primary ignition coil is energized and deenergized, the secondary coil produces a high voltage spike across the
attached spark plugs. At the same time, the tach interface (part of the ignition power transistor) provides the ECM and Transaxle Control
Module (TCM) with an RPM signal.
Part 1 of 2
Part 2 of 2
P0301
P0301, P0302, P0303, P0304
DESCRIPTION
The ignition power transistor, controlled by the engine control module (ECM), provides a switching circuit to ground for energizing the
attached spark plugs. At the same time, the tach interface (part of the ignition power transistor) provides the ECM and Transaxle control
module (TCM) with an RPM signal.
Part 1 of 2
Part 2 of 2
P0302
P0301, P0302, P0303, P0304

DESCRIPTION
Part 1 of 2
Part 2 of 2
P0303
P0301, P0302, P0303, P0304

DESCRIPTION
Part 1 of 2
Part 2 of 2
P0304
P0301, P0302, P0303, P0304

DESCRIPTION
Part 1 of 2
Part 2 of 2
P0335
DTC - P0335 Crankshaft Position Sensor Circuit Malfunction.
Detection Condition
TROUBLESHOOTING
P0340
DTC - P0340
The Camshaft Position (CMP) sensor senses the Top Dead Center (TDC) point of the #1 cylinder in the compression stroke. The CMP
sensor signal allows the ECM to determine the fuel injector sequence starting point.
TROUBLESHOOTING
P0400
DTC - P0400
The Exhaust Gas Recirculation (EGR) system is designed to introduce exhaust gas into the combustion chamber. This lowers combustion
temperatures and reduces the formation of oxides of nitrogen. The amount and timing of exhaust gas introduced into the combustion cycle
varies by such factors as engine speed, engine vacuum, exhaust system back pressure, coolant temperature and throttle position.
TROUBLESHOOTING
P0401
P0401: EGR System - Insufficient Flow Detected
Probable Cause: Hose leak/blockage, basic setting not carried out (if applicable), wiring, EGR valve, EGR solenoid, ECM
For diagnostic information, see TSBs 01-36-021 and 04-36-006
P0403
DTC - P0403
The Exhaust Gas Recirculation (EGR) system is designed to introduce exhaust gas into the combustion chamber. This lowers combustion
temperatures and reduces the formation of oxides of nitrogen. The amount and timing of exhaust gas introduced into the combustion cycle
varies by such factors as engine speed, engine vacuum, exhaust system back pressure, coolant temperature and throttle position.
TROUBLESHOOTING
P0418
P0418: Secondary AIR pump relay B - circuit malfunction
Probable Cause: wiring, AIR pump relay, ECM

Hyundai does not provide any diagnostic information for this DTC.
P0420
DTC - P0420
The ECM compares the waveform of the oxygen sensor located before the catalyst with the waveform of the oxygen sensor located after the
catalyst to determine whether or not catalyst performance has deteriorated.
Air-fuel ratio feedback compensation keeps the waveform of the oxygen sensor before the catalyst repeatedly changing back and forth from
rich to lean.
It the catalyst is functioning normally, the waveform of the oxygen sensor after the catalyst switches back and forth between rich and lean
much more slowly than the waveform of the oxygen sensor before the catalyst.
But when both waveforms change at a similar rate, it indicates that catalyst performance has deteriorated.
TROUBLESHOOTING
P0440
DTC - P0440
The evaporative system reduces hydrocarbon emissions by trapping fuel tank vapors until they can be burned as part of the incoming fuel
charge. Evaporating fuel is stored in a charcoal canister until it can be flushed into the intake manifold.
Part 1 of 2
Part 2 of 2
P0442
DTC - P0442
Troubleshooting Part 1 of 2
Part 2 of 2
P0443
DTC - P0443
Part 2 of 2
P0446
DTC - P0446
The evaporative control system is made up of the following components:

1. Fuel tank which can be completely sealed from outside air.
2. Fuel tank pressure sensor.
3. Fuel/vapor separator which returns raw fuel to the fuel tank and allows only vapors to flow to the canister.
4. Canister close valve which seals the system for testing.
5. A canister filled with granular charcoal.
6. Purge solenoid valve.
In normal operation, the purge control valve opens and closes depending on throttle angle and intake manifold vacuum. When it opens fuel
vapors are flushed from the canister and drawn into the intake manifold. To avoid a vacuum build-up in the canister, the canister close valve
in normally held open to allow fresh air to replace the vapors drawn into the intake manifold.
Part 2 of 2
P0450
DTC - P0450
The Fuel Tank Pressure sensor is used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is
an abnormality in the evaporative emission control system based on the vapor pressure sensor signal.
DTC PO45O is recorded by the ECM when the vapor pressure sensor malfunction.
Part 2 of 2
P0500
DTC - P0500
The Vehicle Speed Sensor is a hall integrated circuit type. The speed sensor converts the transaxle gear revolutions into pulse signals which
are sent to the ECM.
Part 2 of 2
P0505
DTC - P0505
The intake air volume at idle is controlled by opening or closing the Idle Speed Control motor valve provided in the air passage that bypasses
the throttle valve.
Part 2 of 2
P0510
DTC - P0510
The Closed Throttle Position Switch is inside the Throttle Position (TP) sensor. The switch is closed in the idle position (accelerator pedal
not depressed). The ECM controls engine functions by sensing the position of the idle position switch. The TP sensor mounts on the side of
the throttle body and is connected to the throttle blade shaft.
TROUBLESHOOTING
P0551
P0551
Power Steering Pressure (PSP) Sensor/Switch: Range/Performance
Probable Cause: PAS system, PSP sensor/switch
Hyundai does not provide any diagnostic information for this trouble code.
P0700
P0700 Input Pulse from TCM to ECM, Check TCM.
P0705
P0705 Inhibitor Switch Signals Malfunction.
NOTE: Hyundai Motor Corporation has not provided a diagnostic flow chart for this DTC. They do provide a list of remedies in the diagnostic
trouble code descriptions. Refer to Computers and Control Systems / Trouble Code Descriptions / See: Diagnostic Trouble Code
Descriptions/Transmission
P0750
P0750 - Shift Solenoid A Malfunction
TROUBLESHOOTING
P1400
P1400 - Manifold Differential Pressure Sensor Circuit Malfunction
The manifold differential pressure sensor converts intake manifold pressure into a voltage signal. The Engine Control Module (ECM) uses
this signal to determine the condition of the exhaust gas recirculation.
Part 2 of 2
P1521
P1521 Power Steering Pressure Switch signal malfunction, check p/s pressure switch.
P1715
P1715 Open Circuited Pulse Generator A or B
NOTE: Hyundai Motor Corporation has not provided a diagnostic flow chart for this DTC. They do provide a list of remedies or possible causes in
the diagnostic trouble code descriptions. Refer to Computers and Control Systems / Trouble Code Descriptions / See: Diagnostic Trouble Code
Descriptions
Refer to TSBs for updated diagnostic procedures.

DTC 19
DESCRIPTION
- At each wheel hub there is a tone wheel and an inductive sensor, which supplies the wheel speed information to the ABS Control Module
(ABSCM). The sensor comprises a magnet and a pole piece surrounded by a coil. When the tone wheel rotates adjacent to the sensor pole
piece, an alternating current signal is generated in the coil with a frequency proportional to wheel speed.
- A special integrated circuit in the ABSCM translates the generated AC signal to a square wave.
- This square wave is used by the microprocessor to operate the ABS.
WIRING DIAGRAM
- Refer to image for circuit schematic.
INSPECTION PROCEDURE
1. Check Wheel Speed Sensor.

2. Check the harness and the connector between the ABS Control Module (ABSCM) and each wheel speed sensor.
3. Check tone wheel and sensor installation.
DTC 21
DESCRIPTION
- The modulator consists of four solenoid valves, one expander chamber per brake circuit, and a hydraulic pump.
- The ABS Control Module (ABSCM) activates the solenoid valves and controls the pressure to the wheel calipers.
WIRING DIAGRAM
1. Check for voltage between each terminal of the ABS modulator harness.
2. Check the ABS-Modulator.
3. Check the ABS Control Module (ABSCM) harness.

DTC 22
DESCRIPTION
- The modulator consists of four solenoid valves, one expander chamber per brake circuit and a hydraulic pump.
WIRING DIAGRAM

2. Check the harness and connector between the ABS Control Module (ABSCM) and each wheel speed sensor
DTC 23
DESCRIPTION
WIRING DIAGRAM

DTC 24
DESCRIPTION
WIRING DIAGRAM

DTC 25
DESCRIPTION
WIRING DIAGRAM

DTC 26
DESCRIPTION
WIRING DIAGRAM

DTC 27
DESCRIPTION
WIRING DIAGRAM

DTC 28
DESCRIPTION
WIRING DIAGRAM

DTC 31
DESCRIPTION
- At each wheel hub there is a tone wheel and an inductive sensor which supplies the wheel speed information to the ABS Control Module
(ABSCM).The sensor comprises a magnet and a pole piece surrounded by a coil. When the tone wheel rotates adjacent to the sensor pole
piece an alternating current signal is generated in the coil with a frequency proportioned to wheel speed.
WIRING DIAGRAM
1. Check Wheel Speed Sensor

2. Check the harness and the connector between the ABS Control Module (ABSCM) and each wheel speed sensor
DTC 32
DESCRIPTION

WIRING DIAGRAM

DTC 33
DESCRIPTION

WIRING DIAGRAM

DTC 34
DESCRIPTION

WIRING DIAGRAM

DTC 35
DESCRIPTION
- The motor pump relay supplies battery voltage to the motor pump.
- The ABS Control Module (ABSCM) switches the motor relay ON and operates the ABS motor pump.
- If a problem occurs in the ABS system, the ABSCM disables the motor pump relay.
WIRING DIAGRAM
1. Check for voltage between the Relay Box terminal E06-1 and BODY GND. Check motor pump.
2. Check ABS-Relay Box (Motor pump relay).
3. Check motor pump relay.

4. Check resistance between each terminal of ABS Control Module (ABSCM) connector.
DTC 36
DESCRIPTION
- Motor pump relay supplies battery voltage to the motor pump. The ABS Control Module (ABSCM) switches the motor relay ON and
operates the ABS motor pump.
WIRING DIAGRAM
1. Check for voltage between the Relay Box terminal E05 and BODY GND.
2. Check the ABS Relay Box (Motor pump relay).

3. Check the Motor pump relay.
4. Check the resistance between each terminal of the ABS Control Module (ABSCM) connector.
DTC 37
DESCRIPTION
WIRING DIAGRAM


DTC 38
DESCRIPTION
WIRING DIAGRAM


DTC 39
DESCRIPTION
- Motor pump relay supplies battery voltage to the motor pump. The ABS Control Module (ABSCM) switches the motor relay ON and
operates the ABS motor pump.
WIRING DIAGRAM
1. Check for voltage between the Relay Box terminal E05 and BODY GND.
2. Check the ABS Relay Box (Motor pump relay).

3. Check the Motor pump relay.
4. Check the resistance between each terminal of the ABS Control Module (ABSCM) connector.
DTC 41
DESCRIPTION
- Fail safe relay supplies battery voltage to the modulator. After the ignition switch is turned ON position, the relay goes on, if the initial check
is good.
- If a problem occurs in the ABS system, the ABS Control Module (ABSCM)disables the relay and the ABS is disabled.
WIRING DIAGRAM
1. Check ABS power supply.

2. Check the ABS Relay Box (Fail safe relay).
3. Check the Fail safe relay.

DTC 42
DESCRIPTION
is good.
WIRING DIAGRAM


DTC 43
DESCRIPTION
is good.
WIRING DIAGRAM


DTC 44
DESCRIPTION
- If the trouble occurs, the ABS Control Module (ABSCM) lights the ABS-Service Reminder Indicator (SRI) while at the same time
terminating ABS operation. At this time, the ABSCM records a diagnostic code in memory.
- If the ABSCM detects a fault in the Anti-Lock Brake System, the ABSCM turns the ABS SRI on and disables the ABS. At the same time a
trouble code is stored in the ABSCM memory.
WIRING DIAGRAM
1. Check the diagnostic code.

2. Check the ABS Service Reminder Indicator circuit without Relay-Box.
3. Check the ABS Relay-Box.
4. Check the ABS Relay-Box harness.

5. Check the ABS Control Module (ABSCM) connector harness.
6. Check the ABS SRI Circuit.

7. Check the ABS-Relay Box (Fail safe relay).
8. Check the Fail safe relay
DTC 45
DESCRIPTION
WIRING DIAGRAM



DTC 46
DESCRIPTION
WIRING DIAGRAM



DTC 47
DESCRIPTION
WIRING DIAGRAM



DTC 56
POWER SOURCE VOLTAGE
- Detection of battery voltage out of the function range for the system.
WIRING DIAGRAMS
1. Check the ABS Control Module (ABSCM) fuse.
2. Check voltage between Battery (+) and GND of ABSCM connector.

3. Check continuity between the ABSCM connector GND and Body GND.
DTC 57
POWER SOURCE VOLTAGE
- Detection of battery voltage out of the function range for the system.
WIRING DIAGRAMS
1. Check the ABS Control Module (ABSCM) fuse.
2. Check voltage between Battery (+) and GND of ABSCM connector.

3. Check continuity between the ABSCM connector GND and Body GND.
DTC 62
DESCRIPTION
- At each wheel hub there is a tone wheel and an inductive sensor, which supplies wheel speed information to the ABS Control Module
WIRING DIAGRAMS

DTC 63
DESCRIPTION
WIRING DIAGRAMS

DTC 64
DESCRIPTION
WIRING DIAGRAMS

DTC 65
DESCRIPTION
WIRING DIAGRAMS

DTC 66
DESCRIPTION
(ABSCM). The sensor is comprised of a magnet and a pole piece surrounded by a coil. When the tone wheel rotates adjacent to the sensor
pole piece, an alternating current signal is generated in the coil with a frequency proportional to wheel speed.
WIRING DIAGRAM

DTC 67
DESCRIPTION
WIRING DIAGRAM

DTC 68
DESCRIPTION
WIRING DIAGRAM

DTC 69
DESCRIPTION
WIRING DIAGRAM

DTC 71
DESCRIPTION

WIRING DIAGRAM

DTC 72
DESCRIPTION
WIRING DIAGRAM

DTC 73
DESCRIPTION
WIRING DIAGRAM

DTC 74
DESCRIPTION
WIRING DIAGRAM

DTC 77
If a diagnostic trouble code is 77, replace the ABS Control Module (ABSCM) with a new one.
DTC 11
DIAGNOSTIC TROUBLE CODE DESCRIPTION

- Shift timing
- Detect operating area of damper clutch
- Detect throttle position to control fluid pressure during a shift
TROUBLESHOOTING GUIDE
TPS CIRCUIT DIAGRAM
TROUBLESHOOTING FLOW
DTC 12

- Shift timing
TPS CIRCUIT DIAGRAM

DTC 13

- Shift timing
TPS CIRCUIT DIAGRAM
DTC 14

- Shift timing
TPS CIRCUIT DIAGRAM
DTC 15
DESCRIPTION
1. Detect non-operating area of damper clutch.
2. Detect the temperature of ATF as information for fluid pressure control during a shift.
CIRCUIT DIAGRAM
DTC 21
DESCRIPTION
- Detect the point of time when K/D band starts operation to control fluid pressure when K/D band operates.
CIRCUIT DIAGRAM
DTC 22
DESCRIPTION
- Detect the point of time when K/D band starts operation to control fluid pressure when K/D band operates.
CIRCUIT DIAGRAM
DTC 23
DESCRIPTION
- Calculate damper clutch slip.
- Detect engine speed to control fluid pressure during a shift.
CIRCUIT DIAGRAM
DTC 31
DESCRIPTION
- Detect non-operating area of damper clutch
- Detect turbine RPM for control of fluid pressure during a shift
CIRCUIT DIAGRAM
DTC 32
DESCRIPTION
- Detect number of revolutions transfer driven gear to monitor vehicle speed.
CIRCUIT DIAGRAM
DTC 41
DESCRIPTION
Control fluid pressure that is acting on shift control valve (SCV) through
ON/OFF signals from TCM to control shift.
CIRCUIT DIAGRAM
DTC 42
DESCRIPTION
Control fluid pressure that is acting on shift control valve (SCV) through
CIRCUIT DIAGRAM
DTC 43
DESCRIPTION
- Control fluid pressure that is acting on shift control valve (SCV) through
- If resistance value of SCSV-B is high, NO. 43 is output. (open circuit).
- If resistance value of SCSV-B is low, NO. 44 is output. (short circuit).
CIRCUIT DIAGRAM
DTC 44
DESCRIPTION
- Control fluid pressure that is acting on shift control valve (SCV) through
- If resistance value of SCSV-B is high, NO. 43 is output. (open circuit).
- If resistance value of SCSV-B is low, NO. 44 is output. (short circuit).
CIRCUIT DIAGRAM
DTC 45
DESCRIPTION
- Control fluid pressure that is acting on pressure control valve (PCV) through duty signals from TCM to control pressure during a shift.
CIRCUIT DIAGRAM
DTC 46
DESCRIPTION
- Control fluid pressure that is acting on pressure control valve (PCV) through duty signals from TCM to control pressure during a shift.
CIRCUIT DIAGRAM
DTC 47
DESCRIPTION
- Control fluid pressure that is acting on damper clutch control valve through duty signals from TCM to control the operation of damper clutch.
- If damper clutch solenoid drive duty continues at 100% for 4 sec. or more, there is an abnormality in the damper clutch control system a DTC
49 is output.
CIRCUIT DIAGRAM
DTC 48
DESCRIPTION
49 is output.
CIRCUIT DIAGRAM
DTC 49
DESCRIPTION
49 is output.
CIRCUIT DIAGRAM
DTC 51
DESCRIPTION
If the value resulting from dividing the PG-A output (input shaft rotation speed) by the 1st gear ratio does not match the PG-B output (output
shaft rotation speed) after 1st gear is engaged DTC 51 is output.
DTC 52
DESCRIPTION
- If the value resulting from dividing the PG-A output (input shaft rotation speed) by the 2nd gear ratio does not match the PG-B output
(output shaft rotation speed) after 2nd gear is engaged, DTC 52 is output.
DTC 53
DESCRIPTION
- If the value resulting from dividing the PG-A output (input shaft rotation speed) by the 3rd gear ratio does not match the PG-B output (output
shaft rotation speed) after 3rd gear is engaged, DTC 53 is output.
DTC 54
DESCRIPTION
- If the value resulting from dividing the PG-A output (input shaft rotation speed) by the 4th, gear ratio does not match the PG-B output
(output shaft rotation speed) after 4th gear is engaged, DTC 54 is output.
DTC 61
13 - TRANSAXLE CONTROL MODULE
DTC 62
DTC 63
DTC 81
DESCRIPTION
- Detect non-operating area of damper clutch
- Detect turbine RPM for control of fluid pressure during a shift
- If DTC 31 is output 4 times within 10 sec, there is an open circuit in PG-A, fail-safe code 81 is output and the vehicle is locked in 3rd gear
(D) or 2nd gear (2,L) as a fail-safe measure.
CIRCUIT DIAGRAM
DTC 82
DESCRIPTION
- Detect number of revolutions transfer driven gear to monitor vehicle speed.
- If DTC 32 is output 4 times, there is an open circuit in PG-B fail-safe code 82 is output and the vehicle is locked in 3rd gear (D) or 2nd gear
(2,L) as a fail-safe measure.
CIRCUIT DIAGRAM
DTC 83
DESCRIPTION
- Control fluid pressure that is acting on shift control valve (SCV) through ON/OFF signals from TCM to control shift.
CIRCUIT DIAGRAM
DTC 84
DESCRIPTION
- Control fluid pressure that is acting on Shift Control Valve (SCV) through ON/OFF signals from TCM to control shift.
- If resistance value of SCSV-B is high, NO. 43 is output. (open circuit)
- If resistance value of SCSV-B is low, No. 44 is output. (short circuit)
CIRCUIT DIAGRAM
DTC 85
DESCRIPTION
- Control fluid pressure that is acting on Pressure Control Valve (PCV) through duty signals from TCM to control pressure during a shift.
CIRCUIT DIAGRAM
DTC 86
DTC 51 - 86
If the value resulting from dividing the PG-A output (input shaft rotation speed) by the 1st gear ratio does not match the PG-B output (output
shaft rotation speed) after 1st gear is engaged DTC 51 is output.
DTC 52 - 86
- If the value resulting from dividing the PG-A output (input shaft rotation speed) by the 2nd gear ratio does not match the PG-B output
(output shaft rotation speed) after 2nd gear is engaged, DTC 52 is output.
DTC 53 - 86
- If the value resulting from dividing the PG-A output (input shaft rotation speed) by the 3rd gear ratio does not match the PG-B output (output
shaft rotation speed) after 3rd gear is engaged, DTC 53 is output.
DTC 54 - 86
- If the value resulting from dividing the PG-A output (input shaft rotation speed) by the 4th, gear ratio does not match the PG-B output
(output shaft rotation speed) after 4th gear is engaged, DTC 54 is output.
Component Tests and General Diagnostics

CIRCUIT DIAGRAM
USING SCAN TOOL

HARNESS INSPECTION
Monitors, Trips, Drive Cycles and Readiness Codes

Drive Schedule Notes:
1. Coolant needs to be within 0 to 40 C (0 to 104 F) at start.

2. Fuel level must be above 15%.
3. When decelerating from 50-55mph there needs to be at least 5 seconds of fuel cut-off; its best to close throttle as soon as possible for 5
seconds to assure decel fuel cutoff occurs.
4. Try to maintain constant throttle as much as possible during the steady state speed portions of the drive cycle.
Cautions:
1. This schedule is best driven on a dyno if available, otherwise find the best road with least traffic
2. Obey speed limits and drive safely.
3. If you lose the schedule due to traffic, attempt to get back to it when conditions are safe to do so.
4. Keep your eye on the road and avoid looking at the schedule constantly; its best to have a passenger describe the schedule to you while
driving.
Technical Service Bulletins
All Technical Service Bulletins:

Number Date Name
10-FL-013 Nov 10 Fuel System - Fuel Quality Testing
10-BR-001 Oct 10 Brakes - Service Practices & Recommendations
10-EE-003 Aug 10 Electrical - Battery Testing/Equipment/Warranty Info.
10-EM-003 Jun 10 Engine - Oil Pump Replacement Guidelines
10-EM-002 May 10 Engine, Drivetrain - Gray RTV Sealer Update Information
10-AT-008 Apr 10 A/T - Remanufactured Auto. Trans. Program
10-SS-003 Feb 10 Brakes - Brake Fluid Adding/Changing Precautions
10-AT-002 Feb 10 A/T - Specified ATF And Additive Usage
09-BD-011 Sep 09 Body - Sunroof Creaking/Ticking Noises
09-AT-013 Jul 09 A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N
09-FL-006 Jul 09 Emissions - Supplemental EVAP System Diagnostics
09-AT-008 Apr 09 A/T - Stall Test Procedures
09-AT-006 Mar 09 A/T - Specified ATF and Additive Usage Information
09-EM-001 Feb 09 Engine - Unnecessary Crankcase Flushing
09-BD-003 Jan 09 Wheels - Aluminum Wheel Cleaning And Maintenance
08-BE-012 Nov 08 Accessories - Programming Homelink(R) To Garage Opener
08-FL-008 Aug 08 Fuel System - E85 Fuel Usage Recommendations
08-SS-004 Aug 08 Steering/Suspension - Drift/Pull Diagnosis/Repair
08-ST-001 Jul 08 Steering - Power Steering Pump Whine
08-GI-003 Jul 08 Drivetrain - Recreational Towing Requirements
08-BE-004 Jun 08 Electrical - Voltage Drop Diagnostics
08-GI-002 Jun 08 Vehicle - Vehicle Identification Number (VIN) Decoder
08-SS-003 Mar 08 Wheels/Tires - Steering Wheel Shimmy/Vibration
07-40-011 Aug 07 A/T - Cooler Flushing Procedure
07-00-002 Jul 07 Electrical/Instruments - Mercury Disposal/Recycling
07-40-007 Jun 07 A/T - Diagnostic Test Procedures
07-50-003 Mar 07 Brakes - VOC Compliant Brake Cleaner
07-00-001 Feb 07 Vehicle - Perchlorate Material Handling/Disposal
07-50-002 Feb 07 Power Steering - PSF-4 Fluid Compatibility/Part Number
07-99-001 Jan 07 Paint - Cloudy Appearance
06-36-006 Dec 06 Emissions - EGR System Diagnosis
06-40-016 Nov 06 A/T - Automatic Transaxle Fluid Level
tnt1591205-01 Dec 05 Computers/Controls - OBDII DTC List
tnt1581105-02 Nov 05 A/T - No Movement In Drive/Reverse
05-20-005 Nov 05 Fuel System - Fuel Mileage Calculation
05-36-01 Nov 05 Battery - Maintenance/Charging/Diagnostics/Replacement
05-40-016 Oct 05 A/T - No Movement in 'DRIVE' or 'REVERSE'
05-40-012 Aug 05 A/T - Installation Precautions
05-40-007-1 Jul 05 M/T - Gear Lubricant Applications/Interchangeability
05-20-004 Jul 05 Exhaust System - Excessive Sulfur Odors
05-20-002 Jul 05 Engine - Knocking Noise When Using Non-OE Oil Filter
05-80-003 Jul 05 Interior - Manual Seat Installation Procedures
tnt1530505-02 May 05 A/T Controls - DTC Diagnostic Information
05-00-001 Feb 05 Vehicle - RV Towing Guidelines/Precautions
tnt1510205-001 Feb 05 Brakes - Drum Brake Wheel Cylinder Leakage Inspection
04-40-021 Dec 04 A/T - Torque Converter Inspection
04-50-010 Nov 04 Brakes - Rear Drum Brake Wheel Cylinder Leak Inspection
04-80-002 Oct 04 Body - Circular Marks on Interior Glass Surfaces
04-00-002 Jun 04 Vehicle - Towing Requirements & Precautions
04-00-001 May 04 Engine Controls - O2 Sensor Connector Guidelines
04-50-005 May 04 Wheels - Lug Nut Torqueing Service Tips
tnt1430404-001 Apr 04 A/T - Reman A/T Installation Precautions
tnt1430404-003 Apr 04 A/C - A/C Not Cold/No Power To The Compressor
04-20-001 Jan 04 Engine - Oil Filter Information/Applications
04-90-002 Jan 04 Airbags - Replacement After A Collision
03-97-003 Nov 03 A/C - Cabin Air Filter Application Chart
03-36-022 Nov 03 Battery - Cover/Insulation Pad Applications/Installation
tnt1361003-002 Oct 03 A/T - 2-3 Shift Flare or Shift Shudder
tnt1350903-001 Sep 03 Engine Controls - Oxygen Sensor Function/Diagnosis
tnt1350903-002 Sep 03 A/C - Thermistor Component
03-40-015 Aug 03 A/T - 2nd - 3rd Gear Shift Flare/Shudder
03-97-001 Jun 03 A/C - Thermistor Relocation/Part Change
03-90-016 Jun 03 Electrical - Wiring Harness Testing/Repair
03-40-011 Jun 03 M/T - Transaxle Removal and Installation

Number Date Name
03-40-005 Apr 03 A/T - DTC's P0731/P0732/P0733/P0734/P0735/P0736

03-20-001 Feb 03 Engine - Oil Consumption Test Procedure
03-90-001 Feb 03 Audio System - Clicking Noise From Speakers
02-30-001 Dec 02 Emissions - EVAP Leak Code Diagnosis/Repair
02-36-030 Dec 02 Emissions - OBD II Readiness Test Drive Cycles
02-90-005 Jun 02 Audio System - Diagnostic Tips
02-90-009 Jun 02 Security/Alarm System - Diagnostic Guide
02-36-017 Jun 02 Spark Plugs - Application/Service Interval
02-20-004 May 02 Engine - Valve Lash Adjuster Noise
02-40-007 Feb 02 A/T - Torque Converter Clutch Malfunctions
01-90-013 Nov 01 Restraint System - Component Replacement After Collision
01-00-002 Oct 01 Hi-Scan Tool - Software Update Using A PC
01-90-011 Sep 01 Security System - Programming
01-00-002 Aug 01 Vehicle - VIN Decoder
01-90-003 Apr 01 Security Systems - Availability/Applications
01-01-004-1 Apr 01 Recall - Canister Air Intake/Fuel Tank Replacement
01-00-001 Mar 01 Keys - Information For Key Cutting
01-01-004 Mar 01 Recall - Canister Air Filter Replacement
01-40-004 Feb 01 A/T - Remanufactured A/T Program
00-90-008 Dec 00 Air Bag System - Diagnostics
NHTSA00V314001 Oct 00 Recall 00V314001: Fuel Tank/Evaporative System Defect
NHTSA00V314000 Sep 00 Recall 00V314000: Possible Fuel tank Leak & MIL ON
00-50-003 Sep 00 Brake Fluid - Specifications
00-30-003 Sep 00 Enhanced Evaporative Emission Control - Diagnosis
00-00-003 Sep 00 Vehicle Identification Number - Decoder
00-40-012 Sep 00 A/T - Diagnostic Trouble Codes & Scanned Data
00-00-002 Aug 00 Towing - M/T Requirements
00-40-010 Aug 00 A/T - MIL ON DTCs P0712/P0713 Set
00-40-009 Aug 00 A/T - Shift Solenoid Incorrect Operation/MIL ON
00-00-001 Jul 00 Scan Tool - Software Update Procedure
00-50-002 Jun 00 Tires - Defect Inspection Procedures
00-40-004 Mar 00 Remanufactured Automatic Transaxle - Inspection
00-06-001 Mar 00 Head & Tail Lamp - Cleaning Procedure
00-40-001 Jan 00 A/T - Reman, Filler Tube/Dipstick Installation
99-50-011 Dec 99 Brake Rotor - Surface Rust Noise & Pedal Pulsation.
99-50-010 Nov 99 Wheel Lug Nut - Service Tips for Properly Torquing
99-00-009 Nov 99 Brake Rotor - Surface Rust/Noise/Pedal Pulsation
99-00-008 Oct 99 Keys - Cutting Information.
99-90-010 Sep 99 Audio System - Connector Replacement
99-36-014 Sep 99 Engine Performance - Misfire Code Diagnosis
99-99-002 Sep 99 Paint - Bumper Refinishing
99-97-003 Aug 99 Ventilation - Directional Mode Air Flow Distribution
99-36-009 Jul 99 Charging System - Diagnosis
99-40-006 May 99 Deplayed Engagement Into Drive or Reverse
99-50-003 Apr 99 Rear Disc Brake - Minimum Thickness (Manual Addition)
99-90-004 Apr 99 Air Bag Assemblies - Repair Kit Part Numbers
98-36-009 Oct 98 Fuel System - Fuel Injector Diagram Corrections
98-40-010 Sep 98 SP-II Automatic Transaxle Fluid
98-30-002 Sep 98 Enhanced EVAP Control System - Diagnosis And Repair
98-00-002 Sep 98 VIN Decoder
98-99-003 Aug 98 Black Exterior Trim Parts - Refinish Procedures
98-36-006 Aug 98 Engine Coolant Temperature Sensor - Diagnosis
98-40-005 Aug 98 Remanufactured A/T- Program/Cooler Flushing
98-80-007 Jun 98 Wood Interior Trim Kit - Installation Procedure
98-36-004 Jun 98 Spark Plug Wire - Routing, Manual Addition
98-40-002 Apr 98 A/T - Intermittent Delayed, Erratic, Harsh Shifting
98-09-004 Apr 98 Scan Tool Software - Update Information
98-09-003 Apr 98 HDS Scan Tool - Loaner Program
98-80-005 Apr 98 'A' Pillar - Wind Noise at Highway Speeds
98-36-003 Apr 98 Engine Fault Code - Diagnostic Manual Update
98-36-002 Apr 98 Engine Fault Code - Diagnostic Manual Correction
98-36-001 Apr 98 Air/Fuel Mixture - Trim Code Diagnosis
98-90-004 Mar 98 Windshield WIper Blade - Service Procedure

Number Date Name
98-90-005 Mar 98 Airbag Repair Kit - Part Number Update

98-90-002 Feb 98 Keyless Entry Upgrade Kit - Door Solenoid Defect
98-09-001 Feb 98 HDS Scan Tool - Part Numbers.
98-60-001 Feb 98 Body/Interior - Water Leak Detection/Repair
98-50-001 Jan 98 Brake System - Noise Explanation/Diagnosis
98-40-001 Jan 98 A/T - Harsh 4-3 Downshift When Decelerating
97-00-005 Dec 97 Paint - Protection Film MSDS Sheet
97-50-007 Dec 97 Front Brake Disc - Machining Recommendations
97-36-004 Dec 97 Oxygen Sensor- Operation/Diagnosis
97-97-005 Dec 97 A/C - Deodorizing Procedure
97-00-004 Nov 97 Vehicle Identifiication Number - Decoder
97-90-015 Nov 97 Security System - Updates
97-60-006 Nov 97 Spoiler - Installation Instruction Change
97-99-003 Oct 97 Body - Cosmoline Residue Removal
97-40-032 Oct 97 A/T - End Clutch Retainer/Plate Modifications
97-00-003 Oct 97 Engine Compartment - Protective Coating
97-40-031 Sep 97 A/T - Driveability Concerns
Vehicle: All Technical Service Bulletins
Technical Service Bulletin # 08-GI-002 Date: 080601
Vehicle - Vehicle Identification Number (VIN) Decoder

Group: GENERAL
Number: 08-GI-002
Date: JUNE, 2008
Model: ALL MODELS - ALL YEARS
Subject:
1986-2009 MY VIN DECODER
DESCRIPTION:
This bulletin provides information concerning the vehicle identification number (VIN) for all U.S. Specification Hyundai models. For vehicles in
the 2000-2009 model year range, or for vehicles in the 1986-1999 model year range, refer to this TSB for definitions for each of the seventeen (17)
characters in the VIN sequence.Technical Service Bulletin # 01-00-002 Date: 010801
Vehicle - VIN Decoder

Group: GENERAL
Number: 01-00-002
Date: AUGUST, 2001
Model: ALL
Subject:
VIN DECODER
DESCRIPTION:
This bulletin provides information concerning the vehicle identification number (VIN) for all U.S. Specification Hyundai models. Refer to the
illustration for definitions for each of the seventeen (17) characters in the VIN sequence.
Technical Service Bulletin # 98-00-002 Date: 980901
VIN Decoder
Group: GENERAL
Number: 98-00-002
Date: September, 1998
Model: ALL
Subject
VIN DECODER
This bulletin provides information concerning the vehicle identification number of all Hyundai models that have been sold in the United States.
A/C - Deodorizing Procedure

Group: CLIMATE CONTROL
Number: 97-97-005
Date: DECEMBER, 1997
Model: ALL
Subject
A/C ODOR - CLEANING PROCEDURE
This TSB supersedes TSB# 92-97-001
DESCRIPTION:
An Air Conditioning Refresher is available to clean and deodorize vehicle air conditioning systems. The Refresher will assist in the elimination of
musty, unpleasant odors which may come from the air vents when the air conditioner is first turned on in hot, humid climates. This odor may be the
result of debris in the heater/evaporator case and/or microbial growth on the evaporator core.
This refresher is not just a deodorant, but also a two-stage chemical cleaning process. The first cleaning agent is sprayed under pressure to clean
and disinfect the evaporator core and case. The second step rinses and helps inhibit the reoccurrence of odor-causing build up. The rinse leaves a
citrus scent.
An application tool kit is required to perform the operation. The tool kit includes an application wand (for all vehicles except 1986-89 Excels), hose
attachments, hanger, and laminated instructions. An optional wand for 1986-89 Excels is available separately. The A/C Refresher Chemical Kit
contains a single application.
I. Special Instructions For 1995 - Present Sonata

I. Special Instructions For 1995 - Present Sonata:
1. Remove the glove box, main lower dash pad assembly, and lower dash pad cover (see appropriate Shop Manual for details).
2. Mark the evaporator casing.
A. Draw a vertical line that is flush with the left edge of the cover plate boss.
B. Measure 3 inches up from the case joint along the vertical line made in step A.
C. Mark a spot to locate the hole to be drilled.
3. Using a 7 mm drill bit, drill a hole shallow enough to just pierce through the evaporator casing at the location marked from step 2.
CAUTION:
Drill only deep enough to pierce the evaporator case.
4. Go to "Gleaning Instructions: All Models" section in this TSB.

II. For All Excel, Scoupe, 1992-95 Elantra & 89-94 Sonata
II. For All Excel, Scoupe, 1992-95 Elantra, and 1989-94 Sonata:
1. Remove the glove box (On 1986-89 Excel, the glove box does not need to be removed).
2. Disconnect the connector to the blower motor resistor and remove the blower motor resistor assembly.
3. Go to "Cleaning Instructions: All Models" section in this TSB.

III. Special Instruct. For '96 - Pres. Elantra/Tiburon/Accent
III. Special Instructions For 1996 - Present Elantra/Tiburon & All Accent:
1. Remove the glove box, and main lower dash pad assembly (on Accent, the glove box only needs to be lowered).
2. Mark the evaporator casing.
A. Draw a vertical line on the upper half of the evaporator casing that is flush with the left edge of the right side mounting bracket.
B. Measure 2 inches up from the casing joint along the vertical line made in step A.
C. Mark a spot to locate the hole to be drilled.
3. Using a 7 mm drill bit, drill a hole shallow enough to just pierce through the evaporator casing at the location marked from step 2.
CAUTION:
Drill only deep enough to pierce the evaporator case.
4. Go to "Cleaning Instructions: All Models" section in this TSB.

Cleaning Instructions: All Models
1. Place a drain pan under the A/C evaporator drain hose.
2. Attach wand to the spray tool. (An optional wand is required for 1986-89 Excels.)
3. With the ball valve closed, fasten the # 1 aerosol Air Conditioning Cleaner can onto the spray tool snugly.
4. Place the tool hanger around the grooved slot on the spray tool adapter.
5. Hang the aerosol unit upside down, so that it hangs above the passenger door.
6. Insert the wand into the hole that was drilled in the "Special Instructions" section, or into the opening for the blower motor resistor.
Open the ball valve.
7. Push the wand back to the far side of the evaporator. Press the trigger to activate the spray. Using an up and down sweeping motion,
move the wand from the left to the right side of the evaporator. The unit sprays for a little over 30 seconds, so speed is required to
clean all of the evaporator. (Also, for maximum cleaning, hold the wand close to the evaporator without touching the fins.)
8. Remove the empty # 1 aerosol can and close the ball valve. Fasten the # 2 aerosol can onto the spray tool. Hang this unit upside down
above the passenger door.
9. Repeat steps 6 and 7. The air conditioning evaporator is now clean.
10. A. For vehicles that had the blower motor resistor removed, replace the blower motor resistor and reconnect the wiring harness.
B. For vehicles that had an access hole drilled, cut a piece of Scotch Electrical Moisture Sealant (3M - P/N 06149) or equivalent to
cover the drilled hole. Wipe the outside surface of the drilled hole with a clean rag.
11. Replace the glove box, main lower dash pad assembly, and lower dash pad cover.
12. Open both front doors and start the engine. Turn the heat and blower to maximum. Run for about 10 minutes or until all of the
alcohol odor is no longer present.
13. Clean up the area. Remove the drain pan and dispose of the contents as required by your local ordinances.
Note:
Contact your local treatment center for appropriate disposal criteria.
Parts Information
PART NAME PART NUMBER
A/C Refresher Chemical Kit 00232-12100
Tool Kit 00232-12110
Optional 1986-89 Excel Wand 00232-S8100
Body/Interior - Water Leak Detection/Repair

Group: BODY
Number: 98-60-001
Date: FEBRUARY, 1998
Model: ALL
Subject
WATER LEAK DETECTION AND IDENTIFICATION
This TSB supersedes TSB # 95-60-002
DESCRIPTION:
This bulletin provides detection methods and repair procedures for interior water leaks.
DIAGNOSIS PROCEDURE:
First, use the customer's statements to determine the following:

1. Where is it wet? (near the wheel house, in the spare tire well, at the front, at the back, etc.)
2. When does it leak? (while parked level, while parked on a slope, while driving, only during heavy down pours)
3. What color is the moisture? (muddy water from the road surface, clean water from above)
4. How wet? (light dampness after a heavy rain, very wet while/after driving in a drizzle)
Based on the customer's statements, some determinations can be made:
- Location of possible leak points near the damp area.

- Dirty water usually comes from below. Check the wheel house weld seams, floor plugs, lower air vents, etc.
- Clean water usually comes from upper panel surfaces. Check the trunk lid seal, around the windows, sunroof drains, door panel moisture
barriers, etc.
- Leaks noted only while the vehicle is parked are usually associated with water leaking in at one point and seeping to another. Damaged seals
can also leak the same way but may not show visible damage.
Inspection Methods
Flashlight: Shine a strong light on one side of the suspected leak area and look for light on the other side.
Water spray: Use a shower head or sprinkler head to spray water along the suspected leak area. DO NOT USE HIGH PRESSURE WATER (25
PSI maximum). Wait until the leaks begin, and mark the leaks. Spray talcum powder on the dry side of the leak area to make the leaks more
traceable.
Water flow: This test is useful for pinpointing a leak first detected with the water spray test. Direct a flow of water from an open hose to the lowest
point of the suspected leak area. Slowly move the hose upwards until the leak is detected. DO NOT USE HIGH PRESSURE WATER (25 PSI
maximum).
Soap bubble test: Mix 1 part liquid dishwashing soap and 3 parts water in a spray bottle. Spray the mixture onto the inside of the suspected leak
area. Use a blow gun to blow air along the suspected leak area. Use high pressure air for metal to metal weld seams and low pressure (15-30 psi) for
testing rubber seals. The soap will form large bubbles in the leak areas. Along glass runs and door seals, small bubbles will form when too high an
air pressure is used, and large bubbles will form at potential leak points.
Soap bubble test with a pressurized car: Close all of the doors and windows, turn on the ignition key (engine off) and set the blower fan to high in
the fresh air mode. This will pressurize the interior of the vehicle. Spray the dish soap and water solution onto the vehicle exterior over the
suspected leak areas. The soap will form large bubbles where it leaks out. This test can also be used to locate wind leak locations.
Tracing powder: To determine if a seal has consistent contact, spray tracing powder (Kent Industries "Tracing Powder" or 3M "Leak Detection
Powder") onto the metal panel, then shut the panel. The powder should transfer to the seal where the seal has adequate contact.
Ultra sound leak detectors: Place the transmitter in the vehicle and follow along the suspected seam with the detector. Follow the equipment
manufacturer's instructions.
Inspection Examples
Sunroof Area Leaks:
If the car has a sunroof, carefully pour water into the sunroof tray. Water should leak out onto the ground near each of the vehicle tires if the four
sunroof drain tubes are not clogged with leaves or debris, or kinked. Sometimes a kinked drain hose may cause leakage into the passenger
compartment if the sunroof tray does not drain fast enough. Sunroof leaks may travel. A leak onto the headliner may dampen the carpet near the
"A" pillar, or drain through the dome lamp screws.
Door Leaks:
1. If water appears on the floor next to one of the doors, remove the inner door panel.
2. Inspect the door trim seal (or plastic shield) for a complete seal around the edge, and any unusual holes or tears. You can spray the inside
(wet side) of the door trim seal with powdered spray, such as Kent Industries "Tracing Powder" or 3M "Leak Detection Powder".
3. Reinstall the door trim seal, but not the inner door trim panel. Drive the car in the conditions which create the leak. Inspect the area for signs
of water leakage. If the powdered spray was used, look for a trail of powder.
Another area to inspect is door drains. Insure the drains are free and clear and that water can easily exit the bottom of the doors. If it can't, the water
can fill up in the door and spill into the car.
1. Push a wire tie (tie wrap, zip tie) end up each drain hole, or run water from a low pressure hose into the door, to make sure that the door drain
is unobstructed.
2. Use a plastic trim removal tool to create a small gap between the door glass and the beltline moulding at the bottom of the glass.
3. With the door open, pour the water at the glass, letting it drain into the door. The water should drain freely through the drains.
Most blockages can be cleared with a short piece of wire inserted through the drain, but leaves and debris or excess cavity wax may require
removing the inner door trim panel and the door trim seal. Be certain not to scratch the paint inside the door during cleaning, as the scratch may
result in corrosion.
Fresh Air Intake Plenum Leaks:
Water leaks through the fresh air intake plenum may drain through the heater blower motor resistor block connector, or in the area around the
heater blower. Ask the customer when the condition occurs:
- If the leak occurs regardless of fan speed, the cause may be a leaking seam.
- If it occurs after the fan has been operated at a high speed, water may be drawn in with the air.
- If it occurs only during extended rain storms, the leak could be a slow seep.
- If it occurs during car washes as well as rain storms, look for a larger leak.
1. Prepare by removing the plastic cowl top cover at the base of the windshield. Carefully reach inside the cowl to the right side to find the fresh
air intake plenum opening. Make sure that there is no debris around the intake.
2. Run low pressure water from a garden hose into the cowl area, allowing most of the water to drain towards the right side of the cowl. The
water should drain freely through the right fender. If it does not, look for a blockage in the far right side of the cowl area. Use the same
procedure to check the drainage towards the left side of the cowl.
3. Run the water towards the right again. Set the fan to high speed, and select Fresh" air intake. See if any moisture appears around the heater
blower motor area. This may be caused by debris blocking the drainage through the fender. If there are no debris, remove the blower motor
,and fan assembly. Look up into the plenum area to see if any leaks are visible. Use your hand to feel for moisture. Identify the welded seam
that the water leaks through, and apply seam sealer to it. If possible, repair the seam from the outside cowl area.
Front Wheel Well Leaks:
Another source of leakage may be at the mud flap for the front tire. The seam behind the mud flap may get dirt & sand blown into it, essentially
sand blasting the sealer away. As a result, the door sill may fill with water. If necessary, the seam may need to be resealed.
Leak Repair
- Repair leaking seals by repositioning misinstalled seals, or replacing damaged seals.
- Use the appropriate seam sealer listed in TSB # 93-00-007 (Information Concerning Sealants) to correct metal to metal seam leaks. ALWAYS
APPLY THE SEALANT TO THE OUTSIDE OF THE LEAKING SEAM. Failure to do this may result in a new leak in a nearby area. Cover
the under car seam repairs with a spray on undercoating.
- Use 3M Strip Caulk (3M # 8578) or equivalent to repair door moisture barrier seals.
- Use 3M Short Cut Windshield Adhesive Sealant (3M # 08600) or equivalent to seal leaks around windshields, backlights, and fixed side glass.
Warranty Information
Normal warranty operation codes and times apply. If additional time is needed, use actual straight time (TT). Use of additional straight time may
require your DPSM's authorization/approval.
Ventilation - Directional Mode Air Flow Distribution

Group: CLIMATE CONTROL
Number: 99-97-003
Date: AUGUST, 1999
Model: ALL
Subject
VENTILATION: DIRECTIONAL MODE AIR FLOW DISTRIBUTION
DESCRIPTION:
This bulletin provides information describing the air flow distribution characteristics for all Hyundai vehicles.
The air distribution mode control switch permits varying degrees of air flow to the windshield and side defrost nozzles when defrost and/or floor
modes are selected. This feature provides anti-fogging action to the windshield and side windows even when the air is directed to the floor mode. It
is important not to confuse the side defrost nozzles with the dash panel side air vent nozzles (see diagram). The approximate amount of air flow to
the windshield1 floor and dash panel vents is listed in the illustrated table.
AIR DISTRIBUTION MODE TABLE

Deplayed Engagement Into Drive or Reverse

Group: TRANSAXLE
Number: 99-40-006
Date: MAY, 1999
Model: ALL
Subject
DELAYED ENGAGEMENT INTO DRIVE OR REVERSE
DESCRIPTION
Some vehicles may exhibit a delayed engagement into Drive or Reverse after the vehicle has been parked for several hours. This condition may be
due to ATF in the torque converter draining back through a leaking seal inside the oil pump. As a result, when Drive or Reverse are engaged,
several seconds may be required to refill the torque converter.
If the delayed engagement occurs:
^ After the vehicle has been parked more than 8 hours, but does not occur when the vehicle has been parked less than 1 hour, proceed to Service
Procedure.
^ Anytime the vehicle is started and shifted into gear, refer to TSB 97-40-011-1.
SERVICE PROCEDURE:
Attach a scan tool to the Diagnostic Link Connector (DLC) and check for Diagnostic Trouble Codes (DTC). If a DTC is found, repair the condition
and test drive the vehicle again.
If no DTC is found, perform either of the following repairs:
1. Replace the transaxle with a remanufactured transaxle and write on the Core Return Checklist: "Delayed engagement into gear after vehicle is
parked several hours", or
2. Replace the oil pump according to the instructions in the appropriate shop manual.
After installing the oil pump, check the input shaft end play to confirm it is within specification as shown in the shop manual.
WARRANTY INFORMATION:
Normal warranty operation codes and times apply.Technical Service Bulletin # 97-00-003 Date: 971001
Engine Compartment - Protective Coating

Group: GENERAL
Number: 97-00-003
Date: OCTOBER, 1997
Model: ALL
Subject
ENGINE COMPARTMENT PROTECTIVE COATING
DESCRIPTION:
Beginning with September 1st, 1997 production, a clear wax coating has been applied to the engine compartment of all models. This coating is
applied to all aluminum parts to protect against rust and corrosion.
This wax is intended as a permanent coating and should be left on the engine for long term protection.
Air/Fuel Mixture - Trim Code Diagnosis

Group: ENGINE ELECTRICAL
Number: 98-36-001
Date: APRIL, 1998
Model: ALL 1996-98 MODELS
Subject
FUEL TRIM CODE DIAGNOSIS
DESCRIPTION
The Powertrain Control Module (PCM) on Hyundai OBD II vehicles (all 1996 and later models) can adjust the engine Air to Fuel (A/F) ratio to
compensate for variations in operating conditions. This adjustment only takes place during "Closed Loop" operation.
The PCM uses input from the following components to determine the amount of fuel to deliver:
^ Oxygen sensors
^ Air flow sensor
^ Coolant temperature sensor
^ Intake air temperature sensor
^ Throttle position sensor
^ Engine speed sensor
The ability to adjust the A/F ratio enables the PCM to compensate for engine, fuel and sensor variations as well as temperature, altitude and
humidity. This enables the vehicle to maintain a stoichiometric (14.7 to 1) A/F ratio that will ensure optimal engine performance and minimal
emissions.
Since the PCM can change the A/F ratio to compensate for a wide range of conditions, an indicator is needed to identify that a compensation has
been made. Fuel Trim values shown on the HDS scan tool are the primary indicator that an adjustment in fuel delivery has taken place.
The scan tool displays the PCM's A/F ratio compensation as "Short Term" Fuel Trim (ST TRIM), Long Term Fuel Trim (LT TRIM), and "Oxygen
Sensor" Trim (TRIM B1 S1 and B1 S2). The most beneficial diagnostic information comes from Short Term" Fuel Trim and "Long Term" Fuel
Trim.
Short/Long Term Fuel Trim (ST/LT Trim)

^ "Short Term" Fuel Trim is the value that represents the quick small changes the PCM makes to the A/F ratio.
^ On a Sonata, the PCM continuously responds to the signals from the oxygen sensors to maintain the 14.7 to 1 A/F ratio by increasing or
decreasing fuel delivery.
^ On Accent, Elantra and Tiburon, the "Short Term" Fuel Trim indicates the amount of correction at idle and low rpm/load.
^ "Short Term" Fuel Trim values range from -25% to +25%.
^ "Short Term" Fuel Trim values are positive when the PCM is increasing fuel delivery, negative when the PCM is decreasing fuel delivery.
"Short Term" Fuel Trim may read "0.0" for brief periods during transition from positive to negative (or negative to positive) operation. If the
"Short Term" Fuel Trim reads "0.0" for longer periods, it may indicate that the vehicle is in open loop.
^ On a Sonata, the "Short Term" Fuel Trim values are not retained in the PCM memory when the ignition is turned off.
^ On a Sonata, "Long Term" Fuel Trim values change to compensate when the "Short Term" Fuel Trim has reached its limit in one direction and
is unable to maintain the 14.7 to 1 A/F ratio.
^ On Accent, Elantra and Tiburon vehicles, the "Long Term" Fuel Trim indicates the amount of correction at high rpm/load.
^ The "Long Term" Fuel Trim correction range is -25% to +25%. Exceeding the -20% to +20% range will set a code on an Accent, Elantra and
Tiburon. Sonata vehicles will set a code when the -12.5% to +12.5% range is exceeded.
^ On a Sonata, a one digit change of the "Long Term" Fuel Trim value is roughly the equivalent of one entire "Short Term" Fuel Trim range. For
example: when the "Short Term" Fuel Trim reaches its limit, the "Long Term" Fuel Trim moves one digit. This process repeats until the A/F
ratio returns to 14.7 to 1 or the "Long Term" Fuel Trim correction range limit has been exceeded.
^ There is a preprogrammed "Long Term" Fuel Trim correction range that is acceptable for normal operation. When the "Long Term" Fuel Trim
exceeds this range in two driving cycles, the vehicle will set a diagnostic code (DTC), which will illuminate the check engine light.
^ "Long Term" Fuel Trim values are retained in the PCM's memory when the ignition is turned off. This allows the vehicle to "learn" a new fuel
delivery schedule, which is "fine tuned" for optimal performance.
Oxygen Sensor Trim (Trim B1 S1 & Trim B1 S2

^ Oxygen Sensor Trim is the PCM's response value to each individual oxygen sensor input. This value should change similar to the "Short Term"
Fuel Trim values and is not used for diagnostic purposes on Hyundai vehicles
Fuel Trim Diagnostic Codes

A Fuel Trim diagnostic code will set when Fuel Trim values exceed programmed limits due to either "Rich" or "Lean" operating conditions. The
"Long Term" or "Short Term" Fuel Trim numbers stored in the "Freeze Frame" data will indicate if the PCM was increasing or decreasing fuel
delivery when the code was set.
A PCM that is increasing fuel delivery (to compensate for a "Lean" condition) will have a positive (+) "Long Term" Fuel Trim number. A PCM that
is decreasing fuel delivery (to compensate for a "Rich" condition) will have a negative (-) "Long Term" Fuel Trim number.
Accent, Elantra & Tiburon Fuel Trim Codes

^ The "Long Term" Fuel Trim correction range is -25% to +25% on Accent, Elantra and Tiburon. If the "Long Term" Fuel Trim value exceeds
-20% to +20% in two consecutive trips a code will be stored in the PCM.
^ P1123 and P1124 are set at idle, low load and low engine speed operation. Codes set in these operating conditions are sometimes referred to as
additive Fuel Trim correction codes.
Note:
These codes are set when engine speed is less than approximately 1,000 rpm and the air flow sensor reading is less than 5 grams/sec.
^ P1127 and P1128 are set at moderate to high engine load and engine speed operation. These codes are sometimes called multiplicative Fuel
Trim correction codes.
Sonata Fuel Trim Code
^ The Sonata engine management system will only set one Fuel Trim code. Code P0170 will set when the "Long Term" Fuel Trim values are
"Rich" or "Lean" beyond the programmed limits.
^ The "Long Term" Fuel Trim correction range is -12.5% to +12.5% on Sonata vehicles. If the "Long Term" Fuel Trim value exceeds this range
in two consecutive trips, a code will be stored in the PCM.
^ The Fuel Trim values will indicate if the PCM is compensating rich or lean. A PCM that is increasing fuel delivery (to compensate for a "Lean"
condition) will have a positive (+) "Long Term" Fuel Trim number. A PCM that is decreasing fuel delivery (to compensate for a "Rich"
condition) will have a negative (-) "Long Term" Fuel Trim number.
Fuel Trim Code Troubleshooting Tips

1. Using the HDS scan tool, access and write down the Freeze Frame Data (which is the data stored at the time the diagnostic code was set).
This information can give valuable clues about the operating conditions at the time the code occurred and may reduce the amount of
diagnosis and testing required to repair the vehicle.
A. Connect the scan tool and identify the vehicle.
B. Select 1, ENGINE" under the "Select System " menu.
C. Select CODES & DATA MENU from the engine "Main Menu".
D. Select FREEZE FRAME to retrieve the engine operating conditions that were present at the moment the DTC was set.
2. Check the vehicle to identify if codes other than Fuel Trim codes or driveability symptoms are present. A malfunction of any of the following
components may affect the Fuel Trim values:
^ Oxygen Sensors ^ Air Flow Sensor

^ Evaporative Emission System ^ Coolant Temperature Sensor
^ Intake Air Temperature Sensor ^ Fuel Injector
^ Throttle Position Sensor
If codes other than Fuel Trim codes are present, diagnose/repair these conditions before continuing with Fuel Trim diagnosis.
DTC P1124,1128, or P0170 (Positive Fuel Trim Numbers

(The PCM is increasing fuel delivery to compensate for a "Lean" condition)
^ Check for vacuum or unmetered air leaks, concentrating on areas between the air flow sensor and the engine block. Are all the gaskets and
hoses properly installed? A vehicle with a vacuum leak will have an air flow sensor reading that is lower than normal at idle (see Air Flow
Sensor Table in this TSB). Accent, Elantra and Tiburon vehicles with a vacuum leak may also have a low load value.
^ Check the evaporative emission system. An intermittently sticking or stuck open purge solenoid valve may not set an evaporative code in a
1996 or 1997 SOHC Accent or Sonata, but may set a Fuel Trim code.
Check the air flow sensor calibration. If no vacuum leaks are present and the purge system is functioning properly, compare the air flow sensor
reading at idle and at 2500 rpm to the Air Flow Sensor Table. If readings are out of specification, swap the air flow sensor with a known good unit
and re-test.
^ Check the fuel pressure (for low pressure), fuel volume flow (replace fuel filter if necessary), injector part number, PCM part number and
perform the oxygen sensor scan tool test as noted in this TSB.
DTC P1123,1127 or P0170 (With Negative Fuel Trim Number

(The PCM is decreasing fuel delivery to compensate for a "Rich" condition)
^ Check the evaporative emission system. An intermittently sticking or stuck open purge solenoid may not set an evaporative code in a 1996 or
1997 SOHO Accent or Sonata, but may set a Fuel Trim code.
^ Check the air flow sensor calibration. If no vacuum leaks are present and the purge system is functioning properly, compare the air flow sensor
reading at idle and at 2500 rpm to the Air Flow Sensor Table. If readings are out of specification, swap the air flow sensor with a known good
unit and re-test.
^ Check the fuel pressure (for high pressure), the fuel flow (for a return line restriction), the injector part number, the PCM part number and
perform the oxygen sensor scan tool test as noted in this TSB.
Note:
For 1996 Accent SOHC with diagnostic code P1123 only, refer to TSB # 96-36-004 (Powertrain Control Module EPROM Replacement
Procedure).
Note:
The table is supplied as general reference information. If the Fuel Trim conditions occur at different RPM, compare the air flow sensor reading
to a known good vehicle. A "new" vehicle or sensor may read a slightly higher value than normal.
Oxygen Sensor Scan Tool Testing Procedure

1. A. Connect the scan tool
B. Warm up the vehicle to operating temperature (for at least 3 minutes)
C. Select vehicle, year, VIN code, etc.
D. Select "Engine"
E. Select "Data"
F. After OBD II data appears, press "N"

G. Select "Custom Data List"
H. Select "02-B1-S1" and "O2-B1-S2" (front and rear oxygen sensors) and ENG RPM if no tachometer is available.
I. Press "N" and the selected data will appear
2. While holding the engine speed at 2500 rpm in "Neutral" or "Park" (with no load) observe the front and rear oxygen sensors for
approximately one minute. The front oxygen sensor should fluctuate rapidly between 0.095 and 0.995 V. The voltage should read higher than
0.600 V several times and lower than 0.350 V several times. The voltage should never exceed 1.00 V when using the scan tool.
If an Accent, Elantra or Tiburon front or rear oxygen sensor reads a fixed value of 0.425 V to 0.500 V, or a Sonata reads a fixed value of
0.010 to 0.080 V, check for an open/shorted oxygen sensor circuit or no output from the sensor.
The scan tool can also be used to check the sensors while the vehicle is being driven. An assistant is needed to perform this procedure. Use the scan
tool as set up in the previous test procedure.
1. While driving in first gear, accelerate so the engine speed is near 4000 rpm. Quickly release the accelerator and observe the readings from
both sensors. The sensors, should read lean (in the range of 0.20 V down to 0 V) on the scan tool due to the fuel cut-off during deceleration.
2. While driving in first gear, accelerate hard and observe both sensors. The sensors should read rich (in the range of 0.60 V to 1.0 V) on the
scan tool.
A/T - Driveability Concerns

Number: 97-40-031
Group: TRANSAXLE
Date: SEPTEMBER, 1997
Subject: TRANSAXLE DRIVEABILITY (REFERENCE TO ACCELERATOR SWITCH, TPS AND IDLE SWITCH ADJUSTMENT
PROCEDURE)
Model:
ALL
DESCRIPTION:
Correct adjustment of the accelerator switch, throttle position sensor (TPS) and idle switch is essential for proper driveability. An accelerator
sWitch, TPS or idle switch out of adjustment may cause one or more of the following driveability conditions:
^ Park to Reverse or Park to Drive engagement shock

^ Engine speed fluctuation between 1000-1700 rpm during slow cruise at light throttle opening or during deceleration
^ Harsh 4-3 downshift shock when decelerating to a stop
^ Harsh 1-2 and 2-3 upshift
^ Rough idle
It a vehicle has a driveability condition, verify the adjustment of the accelerator switch (if equipped), TPS and idle switch according to the
procedures in the appropriate Shop Manual. These components may be checked using the scan tool (select "4-Speed Trans" menu). Adjust these
components if necessary.
For your convenience, the reference pages in each Shop Manual are listed in this TSB.
Note:
TPS is not adjustable on the OBD-II vehicles listed below. For these vehicles, check the operation of TPS and idle switch at idle and open
throttle using the scan tool (select "4-Speed Trans", "Codes and Data" and "Data" menus).
ACCENT, ELANTRA, TIBURON

SONATA
EXCEL, SCOUPETechnical Service Bulletin # 98-40-001 Date: 980101
A/T - Harsh 4-3 Downshift When Decelerating

Group: TRANSAXLE
Number: 98-40-001
Date: JANUARY, 1998
Model: ALL
Subject
HARSH 4-3 DOWNSHIFT WHEN DECELERATING TO A STOP
DESCRIPTION:
Some vehicles may have a harsh 4-3 downshift when decelerating to a stop. The condition occurs when decelerating at speeds below 5-10 mph and
is likely to be more pronounced when the automatic transaxle fluid (ATF) temperature is cold. If a vehicle experiences this condition, please follow
the diagnostic procedures shown.
DIAGNOSTIC PROCEDURE:
1. Inspect the ATF level in "NEUTRAL" with the ATF at normal operating temperature (70-90°C, 158-194°F).
A. If the fluid level is low, add ATF to bring the level to the top of the "Full" mark.
B. Inspect the ATF color and smell. If the ATF is black and smells burned, remove the transaxle oil pan. If metal particles and clutch
material are found in the oil pan, replace the transaxle.
2. Check that the idle speed is within specification. Adjust, if necessary. (Refer to appropriate Shop Manual, under "Fuel System Section",
"Service Adjustment Procedures".)
3. Attach the scan tool to the data link connector (DLC) and select the "Transaxle" menu.
A. Select "Codes" and check for diagnostic codes (DTC). If DTCs are present, repair the condition.
B. Select "Data" and "Idle Switch". Check that the idle switch reads as shown. If not, adjust or replace the idle switch. (For adjustment
procedures, see TSB # 97-40-029 for 1995-97 Sonata or TSB # 97-40-031 for all other vehicles)
- Engine idling-Idle switch reads "On" or "Closed"
- Engine rpm increased 100-200 rpm above idle-Idle switch reads "Off" or "Open"
C. Select Accelerator Switch" (refer to TSB # 97-40-031 for applicable vehicles). Check that the accelerator switch reads as shown. If not,
adjust or replace the accelerator switch according to TSB # 97-40-031.
- Engine idling Accelerator switch reads "Off" or "Open"
- Engine rpm increased 100-200 rpm above idle-Accelerator switch reads "On" or "Closed"
4. Adjust the kickdown servo to the specification shown in the appropriate Shop Manual, under "Automatic Transaxle" section. Refer to TSB #
96-40-016 for 1990-94 Excels and Sonatas, 1992-95 Elantras or 1991-92 for Scoupes.
5. Note:
Proceed with step 5 for vehicles listed in the table. For all other vehicles, replace the transaxle.
If Steps 1-4 indicate that all components are within specification and no DTCs are found, proceed as follows:
- For the vehicles produced PRIOR to the effective date shown, replace the TCM with the part number shown.
- For vehicles produced AFTER the effective date, replace the transaxle.
PARTS INFORMATION:
Normal warranty operation codes and times apply.

Brake Rotor - Surface Rust/Noise/Pedal Pulsation

Group: GENERAL
Number: 99-00-009
Date: NOVEMBER, 1999
Model: ALL
Subject: BRAKE ROTOR SURFACE RUST NOISE AND BRAKE PEDAL PULSATION
DESCRIPTION:
Surface rust on the brake rotors may occur it a vehicle has been parked for several days in an area where corrosive conditions were present. If the
rotor surface does rust, the area under the brake pads usually remains rust free. The difference in friction between the rusted and unrusted areas may
induce slight brake pedal pulsation, vibration and/or noise for several stops, but will improve as the brake pad friction linings polish the rust off the
rotor.
Typically, three or four stops will polish the rotor surfaces.
If customers inquire about this condition, it may be explained as a normal occurrence. It does not affect brake performance.
Spark Plugs - Application/Service Interval

Group
36 - ENGINE ELECTRICAL
Number
02-36-017
Date
06-2002
Model
All Models
Subject
SPARK PLUG PARTS INFORMATION
This bulletin supersedes TSB # 01-36-001 to update the parts information.
DESCRIPTION:
This bulletin provides the applicable NGK, Denso and Champion Spark Plug part numbers for Hyundai Vehicles.
Table 1: Spark Plug GAP
SPARK PLUG MAINTENANCE:
HOW TO IDENTIFY A PLATINUM PLUG:
NGK/Denso:
The part number starts with the letter "P." Example: P FR5N-11.
CHAMPION:
The 5th letter in the Champion part number is the letter "P." Example: RC10 P YP4.
SPARK PLUG TIGHTENING TORQUE
Recommended tightening torque
^ First, tighten the spark plug finger tight. Once the gasket reaches the cylinder head, use a plug socket and torque wrench to tighten.
Alternate Angle Method:
^ On plugs with crush washers: If the plug is new, insert the plug until the washer makes contact. Then, using a ratchet, rotate the plug a further
90 degrees.
^ If the plug is used, insert the plug until the washer makes contact. Then, using a ratchet, rotate the plug a further 30 degrees.
USING THE CORRECT SPARK PLUG SOCKET
^ Care must be taken during installation that the spark plug socket is not slanted and does not slip causing insulator breakage.
^ The following are qualities required in a wrench:
1. Fits the spark plug "hex" properly.
2. The inner space must be large enough to avoid contact with the insulator.
3. The plug socket must completely cover the "hex" portion of the metal shell.
4. A six-pint socket is preferable as it is less likely to slip than a twelve-point.

SPARK PLUG PART INFORMATION:Technical Service Bulletin # tnt1430404-003 Date: 040401
A/C - A/C Not Cold/No Power To The Compressor

SOURCE: Hyundai Tech Net Times Volume 14 Issue 3 2004
TITLE: No Power To The A/C Compressor
APPLIES TO: All
SERVICE TIP:
If an air conditioner (a/c) is not blowing cold and there is no power getting to the compressor you can use the Hi-Scan Pro to quickly diagnose
the condition. To start, enter the Engine Data menu and scroll down so that you can monitor the "A/C Switch" and "A/C Comp. Relay" (see
example top of the next column)
Start the vehicle and press the a/c switch so the indicator on the dash lights up. Next, use the charts to help find the condition based on the
Hi-Scan inputs you get from the vehicle being tested.
A. The vehicle's ECU has not received an input from the a/c control head. Use a DVOM and test signal voltage from the back of the a/c control
unit to the ECU. If a battery voltage signal is present at the a/c control unit, test for an open in the signal wire or the connection at the ECU.
(See applicable ETM)
B. The ECU has recognized the a/c switch input but is not turning the compressor on for a reason. Confirm the coolant temperature is below 240
degrees F by monitoring the ECT on the Hi-Scan Pro. Confirm the a/c system pressure is normal, if okay bypass the Triple Switch by
jumping pins 1 and 2 in the harness with the switch unplugged. If the compressor comes on with the switch bypassed there is a pressure
problem or the switch is bad. Test the Thermostatic switch in the evaporator according to the appropriate Shop Manual.
C. Check for a ground signal to the compressor relay. If no ground signal is present check the wire for an open between the junction block and
the ECU (see applicable ETM). Confirm that two pins at the relay have power with the key on. The relay is numbered on the bottom side.
Pins 86 and 30 should both have power. Check for an open wire between the relay and the compressor.
Technical Service Bulletin # tnt1350903-002 Date: 030901
A/C - Thermistor Component

TITLE: Thermistor Component And Location Change
APPLIES TO: SANTA FE, SONATA, XG
SERVICE TIP:
A new thermistor is available for Santa Fe, Sonata and XG. See the table below for part numbers and system applications (manually controlled or
full automatic temperature control system).
The location of the thermistor has also been changed. The new location is in the upper corner, toward the rear of the vehicle.
The new location and new part increase the thermal sensitivity of the system to prevent freezing of the evaporator core. The thermistor MUST be
installed in the fins of the evaporator, and on the air outlet (cold air) side of the evaporator.

Engine - Valve Lash Adjuster Noise

Group:
ENGINE MECHANICAL
Number:
02-20-004
Date:
05-2002
Model:
Elantra 1992-1995
Santa Fe 2001-2002
Sonata 1992-2002
Subject:
CHANGE OF HYDRAULIC LASH ADJUSTER ASSEMBLY
DESCRIPTION:
A new hydraulic lash adjuster (P/N 24610-33050) with a larger oil hole has been released to reduce engine noise. The new large hole lash adjuster
has been installed on engines produced beginning October, 2000.
The new lash adjuster assembly may be installed on the engines, if replaced as a set within the engine.
NOTE
DO NOT MIX small hole and large hole lash adjusters within an engine. The oil hole diameter was increased from 1.5 mm (0.059 in) to 3.0 mm
(0.118 in).
Tires - Defect Inspection Procedures

Group: CHASSIS
Number: 00-50-002
Date: JUNE, 2000
Model: ALL
Subject
TIRE DIAGNOSTIC PROCEDURES
DESCRIPTION:
The purpose of this bulletin is to provide information about materials and workmanship related types of tire damage and their coverage under
warranties. When a customer returns a tire for inspection and adjustment, refer to the information in this bulletin to help identify causes of damage
to tires.
There are three categories that can be used to guide tire replacement warranty coverage. They are:
^ Tire workmanship or material detect - Tire Manufacturer's Warranty
^ Road hazard, customer abuse or non-warrantable vehicle mechanical concern - Customer' Responsibility
^ Warrantable vehicle mechanical condition - Hyundai Warranty
Sometimes the cause of tire damage is immediately apparent. In other cases however, only a thorough inspection of the tire will allow determination
of the cause and whether the damage is eligible for replacement under the tire manufacturer's warranty. Thorough inspection requires good lighting,
a clean dismounted tire and close examination of the inner and outer tire surfaces. Finding a point of penetration can sometimes be very difficult
and should be done on a tire spreader.
THINGS YOU SHOULD KNOW ABOUT THE TIRE MANUFACTURER'S WARRANTY:
HANKOOK AND KUMHO TIRES.
^ Hankook and kumho tire manufacturers' warranty coverage include a provision which allows the customer to go to either an authorized
Hyundai dealer or to the Hankook or Kumho tire dealer (as applicable) for tire warranty service. This provision allows for tire warranty service
at the first point of customer contact.
MICHELIN TIRES
^ Michelin tire manufacturer's warranty coverage requires the customer to go to a Michelin tire dealer for tire warranty service.
NOTE:
This TSB is limited to Hankook, Kumho and Michelin tire warranties.
Tire Glossary
BEAD:
The part of the tire that is constructed to hold the tire securely to the rim. It is made of high tensile steel wires wrapped in woven fabric and secured
within the ply ends.
BELT:
Narrow strips of fabric, fiberglass or steel cords running in a circumferential direction immediately under the tread in the crown of a tire (between
the tread and casing plies). They constrict the plies to provide the tire with high lateral stiffness, and act to help the tire resist deformation in its
footprint, and thus give more effective braking and traction. The belts also protect the air chamber against punctures.
CARCASS:
The tire body beneath the tread and sidewalls; also called casing.
CORD:
The strands of material forming the body plies or belt plies of the tire. Cords may be made from aramid, fiberglass, rayon, nylon, polyester or steel.
DOT MARKINGS:
A code molded into the sidewall of a tire signifying that the tire complies with U.S. Department of Transportation safety standards. The DOT code
includes an alphanumeric designator which can also identify the tire's manufacturer, production plant, date of production and brand.
GROOVE:
The space between two adjacent tread ribs or blocks; also called tread grooves.
INNERLINER:
The innermost layer of a tubeless tire. The innerliner prevents air from permeating through the tire.
ORIGINAL TREAD DEPTH (OTD):

Original Tread Depth (OTD) is the tread depth of a new tire measured at the point one-fourth the width of the tire crown section from the crown
center.
OUT-OF-ROUND:
A condition where the tire is not round to within standards due to an uneven distribution of rubber, improper molding, etc.
ROTATION:
The changing of tires from front to rear or from side-to-side on a vehicle according to a set pattern to achieve even tread wear.
SECTION HEIGHT:
The height of the tire, measured from rim to the outer tread.
SECTION WIDTH:
Maximum width of the tire not including any lettering or designs.
SHOULDER:
The area of a tire where the tread and sidewall meet. Also called tread.
SIDEWALL:
That portion of a tire between the tread and bead.
SIPES:
Special slits within a tread block that increase wet and snow traction. Sipes provide more biting edges and allow for the dispersion of water from
under the tread surface.
TIRE PLACARD:
A metal or paper tag permanently affixed to a vehicle which indicates the appropriate tire size and inflation pressures for the vehicle.
TREAD RIB:
The tread section usually composed of many tread blocks that runs around the circumference of the tire, separated by the circumferential tread
grooves.
TREAD DEPTH:
The distance between the surface of the tread and the bottom of the groove of a tire. It is usually measured at a few points located halfway between
the centerline and the edge of the tread.
TREADWEAR INDICATOR:
Narrow bands, sometimes called "wear bars," that appear across the tread surface of the tire when only 2/32 inch of tread remains.
TIRE SIZE:
The size of each tire is indicated by nominal width and rim diameter in inches and millimeters. Radial structure is indicated by the letter "R". For
some tires the aspect ratio is indicated by a percentage.
Conditions Covered By Tire Manufacturer's Warranty
The tires supplied on a Hyundai vehicle are covered against defects in material or workmanship under the tire manufacturer's warranty.
This section provides information on conditions that may be covered by the tire manufacturers' warranties. Review this section and the tire
manufacturers' warranty booklets. If you have any questions, please consult the tire manufacturers' distributors for specific details.
1. TREAD SEPARATION
Partial or complete separation between the rubber and the tire cord or between the layers of the tire cord.
Observation(s):
Check for a bulge on the tire shoulder and a longitudinal crack on the bottom of the grooves, possibly accompanied by a break through the rubber
surface. Both are usually accompanied by localized wear in the tread above the separation.
Prevention:
^ Maintain proper inflation pressure
^ Avoid overloading
^ Drive at a moderate speed
^ Avoid sharp cornering

2. GROOVE CRACKING
Fine longitudinal cracks commonly found in the tread groove base. These cracks do not penetrate into the cord material of the tire. If the tire
continues to be used in this condition, the cracks may join together and may sometimes extend as far as the carcass. Cracking growth is also
increased in underinflated tire conditions.
Observation(s):
Check other tires on the vehicle for this condition. If there are only one or two cracks in the tire groove or if the crack continues up the side of the
groove wall, the cause of the crack is a cut inflicted by a road hazard condition and in that case, the tire is not warrantable.
Prevention:
^ Avoid overloading
^ Remove stone pick-up in the tread grooves
3. SIDEWALL SEPARATION
Localized separation of the sidewall rubber and ply cord or between the plies can occur as shown below. This condition often times appears as a
bulge or bubble and may be felt by hand or with a probe.
Observation(s):
Check tire for proper inflation and observe the tire for absence of scuff marks, abrasion or chafing on the immediate area of damage.
Prevention:
^ Avoid overloading
^ Drive at a moderate speed Avoid sharp cornering
4. OPEN SPLICE
A localized detachment of the rubber stock between the block and sidewall caused by a lack or loss of adhesion where the rubber stock is joined.
An open splice may be a partial opening or a complete detachment and total perforation to the interior
Observation(s):
There should be no evidence of cuts or perforations in the open splice area. The open splice usually displays a smooth angular skive.
Prevention:
^ Avoid overloading
Observation(s):
Check for tine cracks on the tire sidewall. These cracks are generally less than 1/10th of an inch in length and do not penetrate to the interior of the
tire.
Prevention:
^ Store tires properly; keep tires away from direct sunlight, ozone sources, heat, wind, rain, etc.
^ Avoid overloading
5. SIDEWALL CRACKING
Fine cracks on the tire sidewall, running in a radial or circumferential direction. This type of crack may develop on the tire sidewall from ozone in
the atmosphere acting on the rubber. To replace a tire with this condition, refer to tire manufacturer's warranty booklet.
Observation(s):
Check for fine cracks on the tire sidewalk. These cracks are generally less than 1/10th of a inch in length and do not penetrate to the interior of the
tire.
Prevention:
^ Store tires properly; keep tires away from direct sunlight, ozone sources, heat, wind, rain, etc.
^ Avoid overloading
6. BEAD AREA CRACKING
Separation of various tire materials (rubber, cord and wires) at the bead area near the rim line. Some of these can occur as a result of bead flow,
pinched bead or improper assembly of the tire.
Observation(s):
Check tire for a bulge and/or jagged cracks visible near the rim fitting line. Sometimes the cut may not be visible when the tire is mounted on the
wheel.
NOTE:
If the bead rubber is torn as a result of mis-assembly of the tire to the wheel by the assembly plant, coverage is related to the limited new vehicle
warranty and not to the tire manufacturer
Prevention:
^ Maintain proper inflation pressure and avoid overloading
^ Avoid excessive speed and sudden braking
^ Match tires with rim properly and mount tires according to proper procedure
7. INNERLINER SEPARATION
Separation appears as a bulge inside the tire. This condition usually occurs between inner rubber and carcass ply.
Observation(s):
Vehicle vibration, a difficult to balance wheel or ride quality conditions may result from inner liner separation. To confirm this condition, the tire
has to be dismounted. A bulge in the rubber may be visible or can be confirmed by lightly pressing with fingers on the bulged rubber.
Prevention:
^ Avoid overloading
^ Drive at a moderate speed Avoid sharp cornering

Conditions Not Covered By Tire Manufacturer's Warranty
Normal tire wear or wear out is not covered. Road hazard damage such as punctures, cuts, snags and breaks resulting from pothole impact, curb
impact or from other objects, is not covered. In addition, damage from improper inflation, spinning (as when stuck in mud or snow), tire chains,
racing, improper mounting or dismounting, misuse, negligence, alteration, vandalism, or misapplication is not covered.
This section provides information on the types of conditions not covered by the tire manufacturers' warranties. Review this section and the tire
manufacturer's warranty booklet. If you have any questions, please consult the tire manufacturer's distributor for specific details.
1. SUDDEN OR EXCESSIVE FORCE CRACK OR BREAK

Crack or break in tire interior surface. This may be caused by sudden and excessive force applied to the tire exterior which exceeds reinforcing
material limits.
2. TIRE CORD BREAK
A severe side impact can cause the tire cord to break. This can result in a bulge in the sidewall when inflated.
To confirm this condition, look for any scrapes or scratches at or near the bulge, a bent rim flange, or a pinched/cut inner liner.
NOTE:
The above condition should not be confused with sidewall indentations.
3. RUN FLAT
Another example of a road hazard occurs when a tire is grossly under-inflated. This causes the tire to overheat and eventually deteriorate into a run
flat condition.
Prevention:
^ Maintain proper inflation pressure Avoid sudden air loss
4. SIDEWALL CHUNKING
Sidewall may chunk oft as shown. This may be caused by improper installation of a tire chain.
5. TREAD CHUNKING
Pieces of rubber may be torn or chunked out of tire's tread. This chunking may occur during vehicle testing on Dynamometer rolls.
The running condition causing chunk out on a roll test is different and much more severe than conditions encountered during over the road driving.
6. IRREGULAR WEAR
Uneven wear patterns may be caused by improper inflation pressures, misalignment, improper balance or suspension component damage. It should
be suggested to customers that they inspect their tires closely for signs of uneven wear at least once a month.
7. CAMBER or TOE WEAR

Camber or Toe wear indicates misalignment due to misadjusted, loose, worn or bent steering linkage components, or spring fatigue which causes
the vehicle's body to ride closer to the road.
8. SHOULDER WEAR
Under inflation can result in premature wear of both outer edges.
Preventions:
^ Keep proper air pressure in the tires
^ Checking wear patterns of tires regularly
9. CENTER WEAR
Over inflation can result in premature wear of center section of the tire.
Prevention:
^ Keep proper air pressure in the tires
^ Check wear patterns of tires regularly
10. CUPPING WEAR
If tires have not been rotated according to schedule, irregular wear, cupping, and tire noise may result.
11. BRAKE LOCK-UP

Brake lock-up can damage localized areas of the tire.
12. FLAT SPOTTING
Vehicle with flat spotted tire(s) may shake/vibrate at low speeds.
Causes of flat spot:
a. Long shipping period of vehicle with a low air pressure condition in the tires.
b. Keeping the vehicle in storage without change in the parking position. Technical Service Bulletin # 99-50-010 Date: 991101
Wheel Lug Nut - Service Tips for Properly Torquing

Group: CHASSIS
Number: 99-50-010
Model: ALL
Subject: WHEEL LUG NUT TORQUE - SERVICE TIP
DESCRIPTION:
This bulletin provides the proper procedure for torquing the wheel lug nuts.
NOTE: Use of an air impact tool for wheel lug nut installation without the applicable torque limiting socket is not recommended.
Air impact tools typically used for wheel lug nuts can generate up to 300 lb-ft (400 Nm) of torque. Overly torqued and/or unevenly torqued wheel
lug nuts may cause:
- Distortion of the wheel hub
- Distortion of the brake disc
- Brake disc runout
- Brake vibration and pulsation
- Damage to wheel rim
- Damage to the wheel nuts and lugs Steering wheel vibration and shimmy
PROCEDURE:
All wheel lug nuts should be tightened to specification using a torque wrench or using an applicable torque stick (torque limiting impact socket)
supplied by ACCUTORQ (TM) (or equivalent) on a 1/2 inch drive impact tool. The "ACCUTORQ (TM)" lug nut socket limits the torque of the air
impact tool, preventing over tightening or uneven tightening of the wheel lug nuts.
For the correct wheel lug nut torque specification, refer to the appropriate Shop Manual. The chart below summarizes the factory recommended
wheel lug nut specification:
NOTES:
1. Follow the torque pattern as shown below

2. Always use the correct specification ACCUTORQ (TM) lug nut torque socket for the application (color of the tool indicates the torque
specification).
3. Do not use a torque stick to remove wheel lug nuts.
4. Do not use air impact tools on locking wheel lug nuts. They are to be hand-torqued only.
Wheels - Lug Nut Torqueing Service Tips

Group: CHASSIS
Number: 04-50-005
Date: MAY, 2004
Model: ALL
Subject
WHEEL LUG NUT TORQUE - SERVICE TIP
This bulletin supersedes TSB # 03-50-003.
DESCRIPTION:
This bulletin provides the proper procedure for torquing the wheel lug nuts.
CAUTION:
Do not use an air impact tool for wheel lug nut installation without the applicable torque limiting socket.
Air impact tools can generate up to 300 lb-ft (400 Nm) of torque. This amount of torque exceeds the Hyundai wheel lug nut torque specification.
Overly torqued and/or unevenly torqued wheel lug nuts may cause the following:
^ Distortion of the wheel hub
^ Distortion of the brake disc
^ Increased brake disc runout
^ Brake vibration and pulsation
^ Damage to the wheel rim
^ Damage to the wheel lug nuts and lugs Steering wheel vibration and shimmy
PROCEDURE:
All wheel lug nuts should be tightened to specification using a torque wrench or using an applicable torque stick (torque limiting impact socket)
supplied by ACCUTORQ(TM) (or equivalent) on a 1/2 inch drive impact tool. The "ACCUTORQ(TM) "lug nut socket limits the torque of the air
impact tool, preventing over tightening or uneven tightening of the wheel lug nuts.
For the correct wheel lug nut torque specification, refer to the appropriate Shop Manual. The chart summarizes the factory recommended wheel lug
nut torque specification:
1. Follow the wheel lug nut torquing pattern as shown.
2. Always use the correct specification ACCUTORQ(TM) lug nut torque stick for the application (color of the tool indicates the torque
specification).
3. Do not use a torque stick to remove wheel lug nuts.
4. Do not use air impact tools on locking wheel lug nuts. They are to be hand-torqued only. Technical Service Bulletin # 99-99-002
Date: 990901
Paint - Bumper Refinishing

Group: PAINT
Number: 99-99-002
Model: ALL MODELS
Subject: BUMPER PAINT REFINISHING

DESCRIPTION:
This bulletin outlines the basic procedures for refinishing a Hyundai bumper. It applies to both collision repair work and non-collision repair work.
Included are five paint manufacturer's plastic refinish procedures for their products on Hyundai OEM bumpers.
On vehicles where the paint has peeled from the bumper without impact damage or debris damage, warranty repairs may be made inside the normal
paint warranty period with normal authorization approval.
BUMPER REFINISH BASICS:
Basic bumper refinish procedures always involve cleaning and scuff sanding the plastic. This is because the plastics used for most bumpers have a
low "Surface Energy", and they may have residual amounts of contaminants and mold releases on the surface which further reduce the surface
energy.
Surface energy is related to surface tension. Low surface energy (tension) will make the paint bead up on the bumper like water on a freshly waxed
hood. It will not wet the complete surface but will bead up into spots. By thoroughly washing the surface, those contaminants are removed,
increasing the surface energy of the plastic. Scuff sanding with a fine abrasive, such as a 3M Scotchbrite pad or sandpaper, will give the paint a
rough surface to stick to.
BUMPER REFINISH PROCEDURES:
The procedures attached are for the brands of paint listed. Please see your paint supplier to obtain the specific repair procedures for the paint to be
used. All paint procedures have the same general process:
- Clean the plastic
- Scuff the plastic
- Clean the plastic again
- Apply adhesion promoter or special primer
- Apply basecoat / Clearcoat paint
Hyundai bumpers are manufactured using several different types of plastics. The type of plastic the bumpers are made of is molded into the side of
each bumper skin. The chart below summarizes the plastic types for recent Hyundai models. The plastic type may or may not affect the type of
adhesion promoter required.
Parts Information
Paint Manufacturer Procedures

PAINT MANUFACTURER PROCEDURES
The following contain recommended Hyundai bumper painting procedures from five paint manufacturers.
GLASURIT PROCEDURE FOR BUMPER REFINISHING

MARTIN SENOUR PROCEDURE FOR BUMPER REFINISHING

PPG PROCEDURE FOR DBC BASECOAT

PPG PROCEDURE FOR GLOBAL BC COLOR

R-M PROCEDURE FOR BUMPER REFINISHING FOR VARIOUS PLASTICS

SHERWIN WILLIAMS BUMPER REFINISHING PROCEDURE

Warranty Coverage
WARRANTY COVERAGE:
Hyundai warrants the vehicle paint for the first 12 months from the date of the original retail delivey or date of first use, or 12,000 miles, whichever
occurs first (36 months or 36,000 miles for 1998 and newer vehicles), for defects in the materials or workmanship. This coverage does not include
damage due to airborne "fallout", acid rain, rail dust, salt, hail, or "Acts of God". Scratches, dents, impact damage, stone chipping, and similar types
of paint damage are also excluded.
Poor adhesion may be caused by damage to the bumper, or when the bumper is not properly prepared prior to painting. Hyundai will not warrant
the refinish of bumpers when the paint is peeling due to abrasion, impacts, stone chipping, or other physical damage. In addition, Hyundai will not
warrant chemical attack from underhood oils, fluid, coolant, or other underhood chemicals.
Peeling of areas, greater than 2 inches (50 mm) in diameter, where the paint has come off the bumper intact and there is no physical damage, may
be covered. In these areas:
1. Sand the paint on the surface of the bumper until a majority of the paint is removed. In hard to sand areas, remove at least 50% of the paint
over a given area.
2. High pressure wash the bumper to ensure that any remaining paint is well adhered.
3. Wash the bumper

4. Finish sand the bumper with fine sandpaper.
5. Wash the bumper with soap and water and then towel dry with a clean cloth.
6. Follow the paint manufacturer's instructions for solvent cleaning, scuffing and painting.
Spoiler - Installation Instruction Change

Group: BODY
Number: 97-60-006
Model: SONATA
Subject:
SONATA SPOILER INSTALLATION INSTRUCTION CHANGE
DESCRIPTION:
The Sonata trunk mounted spoiler (part no. 00238-B7100) may trap water inside the seal area between the spoiler and deck lid.
A small change has been made to the spoiler installation instructions to alleviate this condition.
SERVICE PROCEDURE:
When installing the foam tape to the spoiler, leave a half inch (1/2") gap at the rear corners of the spoiler (current instructions describes the tape
installation without the gap). This will allow water trapped between the spoiler and deck lid to drain.
Interior - Manual Seat Installation Procedures

Group: TRIM
Number: 05-80-003
Date: JULY, 2005
Model: ALL WITH MANUAL SEATS
Subject
SEAT INSTALLATION PROCEDURES
DESCRIPTION:
This procedure describes how to make the final adjustments to the seat track when installing a seat into a vehicle. After following this procedure,
the seat tracks will easily latch in the forward-backward direction.
PROCEDURE:
1. Remove the seat track end covers and loosen the 4 mounting bolts/nuts. Just loosen them a few turns.
2. Reach under the seat and loosen the 4 seat cushion mounting bolts.
3. Sit in the seat and slide it forward and backward, latching it and releasing it in different places to align the seat tracks.
4. With the seat tracks latched into place with the seat 3/4 of travel to the back, tighten the front nuts securely.
5. Sit in the seat and verify it latches evenly, then move it forward until the rear bolts can be tightened. Tighten the rear bolts.
6. Move the seat back to the 3/4 position, reach under the seat and tighten the seat cushion mounting bolts securely.
7. Verify the seat is properly adjusted and it easily latches into place.
8. Retighten the mounting nuts/bolts to the torque specified in the shop manual.
9. Install the trim coverall the trim covers.
Please refer to the appropriate shop manual for other model year vehicles.
Normal warranty coverage applies. This procedure is part of the seat installation time for procedures that require the seats to be removed and
installed. If a seat requires adjustment without additional parts replacement, use operation code 88003ATT*, N95,
and C31.
A/T - Installation Precautions

Group:
AUTOMATIC TRANSAXLE
Number:
05-40-012
Date:
AUGUST, 2005
Model:
ALL
Subject:
AUTOMATIC TRANSAXLE INSTALLATION PROCEDURE TO PREVENT DAMAGE TO OIL PUMP
DESCRIPTION:
New and remanufactured transaxles are shipped with a retaining strap to hold the torque converter in place. Do not remove the strap until the
transaxle is mounted on the transaxle jack and ready for installation. If the strap is removed prior to this step, the torque converter may move out of
position in the housing.
If the torque converter has moved from the fully inserted position, carefully push inward and rotate the torque converter until the converter is
recessed approximately 9/16 - 5/8" (14-16 mm) into the transaxle case.
If this procedure is not followed, the oil pump may be damaged during installation of the transaxle (refer to example photo showing oil pump
damage).
Remanufactured A/T- Program/Cooler Flushing

GROUP: TRANSAXLE
NUMBER: 98-40-005
DATE: AUGUST, 1998
Model: ALL
Subject
REMANUFACTURED AUTOMATIC TRANSAXLE (ATM) PROGRAM
THIS TSB HAS BEEN REVISED TO DESCRIBE A NEW FLUSHING PROCEDURE FOR THE ATM OIL COOLER.
DESCRIPTION:
The Remanufactured Automatic Transaxle Program has been updated. Warranty policy allows for in-dealership repairs/replacements of the
following components:
^ Axle seal (leaks)
^ End clutch assembly
^ Front pump seal, 0-ring and gaskets
^ Kickdown servo
^ Oil pan (leaks)
^ Oil temperature sensor
^ Pulse generator
^ TCM and/or wiring
^ Solenoids
However, if an internal ATM mechanical condition is diagnosed, remove and replace the ATM with a remanufactured unit. No internal disassembly
of the ATM should be performed. ATM internal overhauls require DPSM prior approval/authorization.
Note:
Second and subsequent remanufactured ATM replacements on the same VIN will require Regional/Technical Assistance Line
approval/authorization prior to performance of repair, and DPSM approval/authorization for claim payment.
TRAINING:
Automatic Transaxle Troubleshooting and Certification Course (# 451300) provides detailed instructions on how to properly diagnose, and when to
repair or replace, an ATM. Regional approval is necessary when installing remanufactured units if your dealership does not currently employ a
technician who has attended this course.
AFFECTED MODELS:
This program applies to all models except 1986 Excels.
SPECIAL SERVICE TOOLS:
Your dealership must have on hand the following Special Service Tools/supplies:
- Hyundai Transmission Cooler Flush (aerosol), P/N 00235-18100
- Hyundai Automatic Transaxle Tester (Kent-Moore # J39853)
- HDS
- HDS Scan Tool (Kent-Moore # J41490)
- HDS Trans-Tech Module
Diagnosis Procedure
1. Service Advisor opens a Repair Order (RO) documenting the customer's detailed complaint. A road test by a Technician or Service Advisor
may be necessary to verify the customer's description.
2. The Service Advisor carefully completes the top section of the ATM Diagnosis Worksheet.
3. The Worksheet (P/N NP150-07006) and shop copy of the RO are dispatched to the Technician. (The remaining copies of the RO can be
broken out and distributed according to established dealership procedures).
4. Technician follows Diagnostic Flow Chart on the back of the Worksheet to help complete the diagnosis of the ATM and to make a
repair/replace decision.
5. If it is determined that a remanufactured unit must be ordered/installed, the technician must obtain the Service Manager's approval and
signature on the Worksheet.
6. If a remanufactured unit is necessary, the technician sends both the Worksheet and RO to the Parts Department.
7. Parts Department orders remanufactured ATM from the facing PDC and retains RO and Worksheet, filed by RO number.
8. Parts Department receives remanufactured ATM, shipped prepaid in a reusable box, and provides ATM to Technician.
Note:
Retain reusable box and use to return removed ATM and torque converter to the remanufacturing center.
A complete package of forms is included with each remanufactured ATM unit as shown.
- Core Return Checklist - Pre-addressed shipping label

to remanufacturing center
- Bill of Lading - Installation tips

9. Parts Department completes all required fields of information on the Core Return Checklist. Failure to do so will result in debit.
10. Technician completely drains all fluids, removes the ATM and torque converter from the vehicle.
Note:
Do not disassemble any part of the ATM.
11. Flush the transaxle oil cooler and hoses using Hyundai Transmission Cooler Flush (part no. 00235-18100). Follow instructions in TSB #
98-40-004.
12. Install the remanufactured ATM according to the appropriate Shop Manual. Fill the ATM fluid to the specified level using Genuine Hyundai
ATF+ Type 7176 or SP-II.
13. Secure the removed torque converter to the removed ATM core using the torque converter retaining strap and bolts removed from the
remanufactured ATM unit.
14. Install all plugs removed from the remanufactured ATM unit onto the removed ATM unit before packaging to prevent residual fluid from
leaking.
15. Place the top copy of the ATM Diagnosis Worksheet and the top copy of the Core Return Checklist into the plastic bag provided with the
remanufactured ATM unit and close the envelope securely. Enclose all needed forms and ensure they are completed and fully filled out.
Note:
Failure to properly complete and/or return the designated ATM Core Return Checklist and ATM Diagnosis Worksheet will result in a $50.00
reduction of the core credit and/or charge back of your warranty claim.
16. Place the removed ATM into the shipping container provided with the remanufactured ATM (make sure that the ATM is placed in the proper
direction); secure lid with retaining straps.
17. Using the address label provided with the remanufactured ATM unit, ship the removed ATM with the Core Return Checklist.
Note:
Freight charges are paid by HMA for returning the removed ATM to the remanufacturing center, if the enclosed bill of lading is used and ATM
is shipped via HMA approved carriers. DO NOT SUBMIT A WARRANTY CLAIM FOR THESE CHARGES.
18. The bottom copy of the Core Return Checklist is retained in the dealership's Parts Department, filed by the repair order number indicated in
the top right hand corner of the checklist.
19. The canary copy of the ATM Diagnosis Worksheet must be attached/retained with the shop copy of the RO in the Dealership's VIN service
files. Dealership must record the removed and remanufactured ATM serial numbers on the shop copy of the RO.
20. Remanufacturing center receives the removed ATM, Core Return Checklist and ATM Diagnosis Worksheet.
21. Remanufacturing center checks documents and sends forms to HMA.
22. Dealer is reimbursed for core ATM.
Note 1:
Second and subsequent ATM reman replacements on the same VIN will require Regional/Technical Assistance Line approval/authorization
prior to performance of the repair and DPSM approval/authorization for claim payment
Note 2:
HMA may deny/chargeback all or portions of ATM claims and/or core credits on remanufactured units if:
- Cooler not properly flushed, causing remanufactured ATM to fail
- Remanufactured ATM damaged due to:
- Improper handling
- Improper installation/removal
- Improper Packaging
- No trouble found/incorrect diagnosis
- Comeback repair/incorrect diagnosis
- Incomplete or missing Core Return Checklist and/or ATM Diagnosis Worksheet

Note 3:
Dealers must contact their facing PDC regarding lost packaging and paperwork.
Note 4:
Dealer Parts Department accepts full responsibility for insuring that transaxles sold over the counter:
- Have an ATM Diagnosis Worksheet that is completely and accurately filled out
- That the ATM cooler is flushed to HMA specifications using Hyundai Transmission Cooler Flush (part no. 00235-18100)
- Genuine Hyundai Transmission fluid (ATF+ Type 7176 or SP-II) is used to refill the ATM
NOTE:
*The ATM oil cooler and hoses must be flushed prior to installation of the replacement remanufactured ATM. If a thorough flushing is not
performed, the remanufactured ATM can be contaminated by debris left in the cooler and hoses, resulting in shop comebacks and possible
claim chargeback.
**Diagnostic before and after readings/measurements must be recorded on the ATM Diagnosis Worksheet whenever the ATM Tester, Scan
Tool, or HDS is used. The Worksheet (canary copy) must be retained with the shop copy of the RO. In addition, if the HDS is used, a printout
of the readings must also be retained with the shop copy of the RO.
A/T - Torque Converter Clutch Malfunctions

Group: TRANSAXLE
Number: 02-40-007
Model: ALL
Subject:
AUTOMATIC TRANSAXLE TORQUE CONVERTER CLUTCH DIAGNOSIS
DESCRIPTION:
The torque converter clutch (TCC) inside the torque converter, also referred to as the "damper clutch" or "lockup clutch", functions to lock the
input and output sections of the torque converter together to provide improved fuel economy.
If you are servicing a transaxle with either of the following conditions, follow the repair procedure shown below:
^ Torque converter clutch does not engage when driving at steady speed on the highway.
^ Engine stalls when coming to a stop or when shifting into Drive or Reverse
REPAIR PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 01-40-013. Adjust the ATF level as needed.
2. Attach the Hi-Scan Pro and check for Diagnostic Trouble Codes (DTC) in both the "ENGINE" and "AUTOMATIC TRANSAXLE" menus.
If the DTC shown are found, follow the repair procedure shown. If no DTC are found, go to Step 3.
3. Using the Hi-Scan Pro, select "HYUNDAI VEHICLE DIAGNOSIS", "AUTOMATIC TRANSAXLE" and "CURRENT DATA" menus, then
"OIL TEMPERATURE" or "FLUID TEMPERATURE". Confirm the oil temperature readout is correct as shown. If not, replace the oil
temperature sensor.
4. Using the Hi-Scan Pro, select:
^ "HYUNDAI VEHICLE DIAGNOSIS" menu
^ "AUTOMATIC TRANSAXLE" menu
^ "CURRENT DATA" menu
^ THROTTLE P. SENSOR, "TCC SOLENOID DUTY", "TCC SLIP" and "OIL TEMPERATURE"
^ F2 - "SCRN". This will isolate the top four data to allow a quicker refresh rate for the data.
^ Check the TCC data under the conditions shown in the table. If the TCC data indicate as shown, the torque converter and damper clutch
are operating correctly. If not, go to Step 5.
5. If the TCC data does not indicate as shown or the engine stalls, follow the repair procedure shown.
6. If the engine stalls when shifting into Reverse or Drive, the oil cooler may be restricted. Disconnect the oil cooler hoses to the oil cooler in
the radiator. Bypass the oil cooler as shown. It the condition:
^ Does not recur, replace the radiator
^ Recurs, contact the technical assistance line 800-325-6604.
NOTE:
Normal Warranty Labor Operation Codes, and Claim Submission Procedures apply to the applicable repair performed.
A/T - Shift Solenoid Incorrect Operation/MIL ON

Group:
TRANSAXLE
Number:
00-40-009
Date:
AUGUST, 2000
Model:
ALL
Subject:
AUTOMATIC TRANSAXLE SOLENOID DIAGNOSTIC TROUBLE CODES
DESCRIPTION:
Incorrect operation of the transaxle solenoids may result in the following symptoms:
^ Erratic shift
^ Transaxle held in 3rd gear Fail-Safe
^ Diagnostic Trouble Codes (see list in "DTC Information")
^ MIL illuminated
NOTE:
Do NOT replace the transaxle for solenoid codes listed as "Electrical Condition" in the "DTC Information" section of this bulletin. Instead,
follow the repair procedure shown below.
REPAIR PROCEDURE:
1. Using a Hi-Scan Pro, select: "Hyundai Vehicle Diagnosis" menu, "Automatic Transaxle" menu and "Diagnostic Trouble Codes". Repeat the
procedure and select "Engine" menu and "Diagnostic Trouble Codes". Record the DTC and description.
NOTE:
Steps 2-5 are only for Elantra/Tiburon prior to 2001 MY and all Accents. For other models, go to Step 6:
2. Clean the connection between the battery cables and the battery posts.
3. Clean the connection between the negative battery cable and the transaxle case. Reinstall the cable.
NOTE:
This procedure is necessary because the solenoids ground through the transaxle case and negative battery cable.
4. Clean the connection between the negative battery cable and the body ground bolt located next to the battery. Apply conductive grease to the
connection before reinstalling the bolt.
NOTE:
This procedure is necessary because the TCM grounds through this body ground.
5. Measure voltage drop:
^ Start the engine and turn on the headlights.
^ Use a digital voltmeter to measure the voltage drop between the negative battery terminal and the ground locations in Steps 3 and 4 (use
VDC setting). If the voltage drop is:
More than 0.1 volts: Replace the negative battery cable
Less than 0.1 volts: Go to Step 6
All models:
6. Disconnect the connectors between the solenoid and TCM. Check for bent pins or pins not fully inserted in the connector. Repair as
necessary.
NOTE:
Clean connector pins with a contact cleaner listed below, or equivalent:
^ NAPA Electronic Cleaner, P/N 765-1843
^ MOPAR MP-50 Electrical Contact Cleaner, P/N 04549626
^ Permatex Electrical Contact Cleaner, P/N 24379 or equivalent.
7. Check the wiring harness in the engine compartment and inside the transmission oil pan for a damaged wire or a short circuit to ground.
8. Measure the resistance of the harness wires between the solenoid connector and TCM connector. Refer to the appropriate ETM to find the
correct pin terminals. If the resistance is:
^ More than 1 ohm: Repair the harness
^ Less than 1 ohm: Go to Step 9.
9. Refer to the DTC recorded in Step 1. If the DTC was:
^ Solenoid DTC, except P0740 or 49: Replace the related solenoid or solenoid assembly
^ DTC P0740 or 49: Replace the transaxle.

NOTE:
For 1999-2001 Sonata or 2001 Elantra, XG or Santa Fe, refer to the Automatic Transaxle Overhaul Manual, Page 45D-51, to locate the related
solenoid.
10. Clear the codes and test drive the vehicle for two driving cycles (two key-on to key-off driving cycles, including 1-2-3-4 upshifts and 4-3-2-1
downshifts). If the DTC return, replace the TCM.
DTC INFORMATION:
For your reference, the logic the TCM uses to set solenoid codes are listed.
DO NOT replace the transaxle for those codes listed as "Electrical Condition". Refer to the tables for additional information.
TCM DTC - 1999-01 SONATA, 2001 ELANTRA, XG & SANTA FE

2000-01 ACCENT, 1999-00 ELANTRA (produced after 6/1/99):
TCM DTC - 1996-99 ELANTRA/TIBURON (PRIOR TO 6/1/99), & 1996-99 ACCENT:

TCM DTC - PRE-OBDII: ELANTRA, TIBURON AND ACCENT PRIOR TO 1996, 1995-98 SONATA:
ECM DTC - (1995-98) SONATA):
NOTE:
Only the 1996-98 Sonata has an ECM DTC that indicates a transaxle condition. If you find P0750 in the ECM, check the "Automatic
Transaxle" menu for additional DTC information.
WARRANTY INFORMATION
A/T - Torque Converter Inspection

Group: TRANSAXLE
Number: 04-40-021
Model: ALL MODELS

ALL YEARS
Subject
AUTOMATIC TRANSAXLE TORQUE CONVERTER
INSPECTION
DESCRIPTION
Prior to installation, please inspect all transaxle torque converter mounting holes according to the Repair Procedure shown below.
REPAIR PROCEDURE
1. Loosen the l4mm bolt securing the shipping strap to the transaxle. Remove the bolt that secures the shipping strap to the torque converter.
Check if the bolt is a "Star" bolt, (M10 x 1.25 x 11 mm, P/N 42121-21720):
^ IF NOT, discard the bolt
^ IF SO, retain the bolt
2. Use a light to inspect all the mounting bolt holes and threads for:
^ An interference mark at the bottom of the hole indicating the existing bolt or a previous bolt has bottomed out and damaged the torque
converter.
^ Stripped threads caused by a bolt with incorrect threads.
A mark indicating the existing bolt or a previous bolt has bottomed out:
Damage caused by a bolt with incorrect threads:
If the inspection shows:
^ No damage to either the mounting bolt hole or bolt threads - install the transaxle using '~Star bolts to install the torque converter to the
engine drive plate.
^ Damage to either the mounting bolt hole or bolt threads:
^ Install the shipping strap and use a "Star" bolt to secure the torque converter.
^ Write "Bolt holes damaged" on the Core Return Checklist.
^ Return the transaxle to the remanufacturer following the normal procedure. Technical Service Bulletin # 98-36-009 Date:
981001
Fuel System - Fuel Injector Diagram Corrections

Group
Number
98-36-009
Date
10-1998
Model
Sonata 1996-1998
Subject
1996-98 SONATA FUEL INJECTOR CONFIGURATION (SHOP MANUAL AND ETM CORRECTIONS)
DESCRIPTION
Some of the fuel injector illustrations in the 1996-98 Sonata Shop Manuals and 1996-98 Sonata Electrical Troubleshooting Manuals (ETM) are
mislabeled.
The correct configuration of fuel injectors is shown. Please refer to figure shown for an illustration of the corrections.
Please record the corrections in the appropriate manuals and write the TSB number on the bottom of the pages listed below for future reference.
AFFECTED SHOP MANUALS AND PAGES
^ 1996 Sonata Shop Manual Vol. II: Page SD-73

AFFECTED ETM AND PAGES
^ 1995/6 Sonata ETM: Page 24 and 24-10

^ 1997 Sonata ETM: Page SD-76
^ 1998 Sonata ETM: Page SD-76
Scan Tool - Software Update Procedure

Group: GENERAL
Number: 00-00-001
Date: JULY, 2000
Model: ALL
Subject
HI-SCAN PRO SOFTWARE UPDATE PROCEDURE
DESCRIPTION
This bulletin details the procedure for updating the Hi-Scan Pro Software Cards. New software for the Hi-Scan and for reprogramming vehicle
Engine Control Modules (ECM) and Transaxle Control Modules (TCM) will be provided periodically via the Hyundai Service Web Site
(www.hmaservice.com) and HDS CDROM updates.
PROCEDURE:
Three software cards are included in the Hi-Scan kit:
^ The "SOL" card contains the main program that operates the Hi-Scan; reading codes and data.
^ The "Reprogramming" card is used for reprogramming ECMs and TCMs for campaigns and field fixes.
^ The "INFO" card contains additional diagnostic tips and information that are not on the standard SOL card.
An RS232 communication cable is included in the Hi-Scan kit. This cable is used to connect the Hi-Scan to the HDS for data transfer.
1. Connect the RS232 cable to the 9-pin COM port on the back of HDS.
2. Connect the other end of the RS232 cable to the COM port on the left side of the Hi-Scan.
3. Provide power to the Hi-Scan using the cigarette lighter power adapter.
4. Insert only the software card you (wish to update into the Hi-Scan.
5. Make sure the "Write Protect Tab" is set to the right. Setting the tab to the right enables new software to be written to the card.
If the tab is to the left, an error will occur during the update process.
Note:
It is OK to leave the INFO card in the Hi-Scan while updating either the SOL or Reprogramming cards.
6. Turn the Hi-Scan ON and select "Data Down Load" from the main menu.
7. From the HDS Info-Tech home screen, click the "Scan-Tool Update" button to launch the update utility.
8. Note the brief instructions on the left of the screen and click the "51W Download" button.
9. Select the new software from the "File List".

To avoid confusion, the three different types of software start with an identification letter:
S - = Software for the SOL card

R - = Software for the Reprogramming card
I - = Software for the INFO card
Example: "S-System 04-28-00.dat" is software for the SOL card.
10. Select the proper "Port" setting
COM1 is the default setting and should work for most systems.
If the program does not transfer the software to the Hi-Scan, try changing the "Port" setting to COM2.
11. Select the proper "Data Type"
"Standard Pack" is the default setting and is used when updating the SOL and Reprogramming software cards.
"Trouble Shooting Pack" is used only for updating the INFO software card.
COM1 is the default setting and should work for most systems.
If the program does not transfer the software to the Hi-Scan, try changing the "Port" setting to COM2.
12. Click the "Write" button to start the download process.
13. The progress meter at the bottom indicates the percent complete.
It will take approximately 5 minutes for the file to download to the Hi-Scan.
14. The Hi-Scan screen also displays the download progress.

15. After the file has finished downloading, turn the Hi-Scan OFF and then back ON to use the new software.
NOTE:
If for any reason the download process is interrupted before completion, the software on the software card may become corrupted. Indications
of a corrupted card or blank card are a flashing screen and beeping when the Hi-Scan is turned ON.
To restore the corrupted software card, hold down the "Shift" and "F1" keys on the Hi-Scan while pushing the ON button. This puts the Hi-Scan
into Software Download mode immediately. Try the download process again as shown starting at step 1.
16. To check the software version, select "System Setup".

17. Then select "System Configuration"
18. The "S/W Card Ver." shows the current software version.
A/T - Diagnostic Trouble Codes & Scanned Data

Group
TRANSAXLE
Number
00-40-012
Date
SEPTEMBER, 2000
Model
ALL
Subject
AUTOMATIC TRANSAXLE DIAGNOSTIC
TROUBLE CODES
DESCRIPTION:
If you are servicing a vehicle with a driveability condition, please select the "Hyundai Vehicle Diagnosis" menu, then check for Diagnostic Trouble
Codes (DTC) in both the "Engine" and "Automatic Transaxle" menus. Record the DTC and the descriptions.
NOTE:
Ensure the latest (4/28/00) software has been downloaded into your Hi-Scan Pro, so it is no longer necessary to check the "CARB OBDII"
menu for DTC (see TSB 00-00-001).
Automatic transaxle DTC are found in the following menus:
If transaxle DTC are set and the MIL is illuminated, codes P1624 and P1529 will be displayed in the "Engine" menu. The purpose of the DTC is to
advise that the TCM requested the ECM to turn on the MIL (the TCM does not have the authority to turn on the MIL).
SENSOR INPUTS TO TCM:
The sensor inputs to the TCM can be checked by selecting:
^ "Hyundai Vehicle Diagnosis" menu
^ "Automatic Transaxle" menu "Current Data" menu
If you wish to show the sensor data as a graph:
^ From the "Automatic Transaxle" menu, select "Current Data" menu
^ Highlight the desired sensor and select "FIX" (F1). Repeat for an additional sensor, if desired.
^ Select "GRPH" (F5).
If you wish to record the graphed data:

^ From the "Automatic Transaxle" menu, select "Flight Record" menu
^ Highlight the desired sensor and select "FIX" (F1). Repeat for an additional sensor, if desired.
^ Select "RCRD" (F6)
^ Select "TRIG" (F5) to begin recording
^ Select "END" (F6) to stop recording
^ Select "GRPH" (F1)

Engine Coolant Temperature Sensor - Diagnosis

Number: 98-36-006
Date: AUGUST, 1998
Model: ALL
Subject
ENGINE COOLANT TEMPERATURE SENSOR DIAGNOSIS
DESCRIPTION:
The engine coolant temperature sensor is located in the coolant passage of the cylinder head. It detects engine coolant temperature and sends signals
to the powertrain control module (PCM). The engine coolant temperature sensor uses a thermistor which is sensitive to changes in temperature. The
electric resistance of a thermistor decreases in response to a rise in temperature. Thus, when the temperature increases, the output voltage decreases
The PCM determines engine coolant temperature by the sensor output voltage and provides optimum fuel enrichment when the engine is cold.
This bulletin provides diagnosis and repair procedures for engine coolant temperature sensors.
DIAGNOSTIC PROCEDURES:
DTC: Diagnostic Trouble Code
PCM: Powertrain Control Module
ECT: Engine Coolant Temperature
DIAGNOSTIC HINTS:
1. If the fast idle speed is not high enough or if the engine produces dark smoke during engine warm-up operation, a malfunctioning engine
coolant temperature sensor might be the cause.
2. If the thermostat opening state is abnormal and causes overcooling, the Diagnostic Code (DTC) for the engine coolant temperature sensor can
be set.
3. The Malfunction Indicator Lamp (MIL) is on or the DTC is set under the following conditions:
a. When the engine coolant temperature is detected by the sensor as below -40°C or above 120°C.
b. If the engine coolant temperature does not increase at least 5°C, even though 130 seconds or more have elapsed after starting the
engine.
USING A VOLTMETER:
USING A SCAN TOOL:
HARNESS INSPECTION PROCEDURES:
SENSOR INSPECTION:
1. Remove the ECT sensor from the intake manifold.
2. With the temperature sensing portion of the ECT sensor immersed in hot water, check resistance.
3. If the resistance deviates from the standard value (as shown on the chart), replace the sensor.
INSTALLATION:
1. Apply sealant (LOCTITE962T or equivalent) to the threaded portion of the sensor.
2. Install ECT sensor and torque to 11-15 lb.ft.
3. Reconnect the harness connector securely.

Oxygen Sensor- Operation/Diagnosis

Number: 97-36-004
Model: ALL OBD-II VEHICLES
Subject
OXYGEN SENSOR DIAGNOSIS
Description
An oxygen sensor measures the amount of oxygen present in the exhaust gas. The oxygen sensor "element is coated with a catalyst metal that
produces a small voltage from 0 to 1.00 volt at temperatures in the range of 600°F (315°F) when exposed to oxygen. The "stoichiometric" air4uel
mixture for optimum fuel economy and emissions occurs at approximately 0.50 V. When the oxygen sensor output signal is above 0.50 V, the
air-fuel mixture is considered rich and when the signal is under 0.50 V it is considered lean.
Hyundai OBD II engine management systems (1996 and later models) include two heated oxygen sensors (heated oxygen sensors allow the vehicle
to go into closed loop in 20 to 30 seconds to reduce emissions):
- The "upstream" (front) oxygen sensor is located in the exhaust stream before the catalytic converter. The front sensor provides feedback to the
PCM that is used to identify if the air-fuel mixture supplied to the cylinders is rich or lean. Under normal operating conditions, the front oxygen
sensor signal will fluctuate from 0 to 1.00 V. The front sensor signal should fluctuate, crossing the 0.50 V center about seven times in 5 seconds
with the engine held at a steady 2500 rpm, when the vehicle is at operating temperature (the signals cannot be seen when viewing with the scan
tool because the scan tool's refresh rate is not fast enough; Hyundai Diagnostic System (HDS) can be used (see "HDS Testing Procedure" in this
TSB)).
- The "downstream" (rear) oxygen sensor is located after the catalytic converter in the exhaust stream. The rear sensor provides feedback to the
PCM to "fine tune" the air-fuel ratio and to monitor catalytic converter efficiency. The rear sensor signal will also fluctuate in the 0 to 1.00 V
range but the pattern is less predictable than for the front oxygen sensor because of its position in the exhaust system. Once the catalyst has
reached operating temperature, the rear sensor signal should change very little, if at all. If the rear sensor signal fluctuates at approximately the
frequency of the front sensor, it is an indication that the catalytic converter is not at operating temperature or is malfunctioning.
Oxygen Sensor Diagnosis
A properly operating oxygen sensor may have unusual signal characteristics that are the result of other components. A malfunction of any of the
following components may affect sensor signal characteristics:
^ Fuel injector(s)
^ Air flow sensor
^ Evaporative emission system

^ Barometric pressure sensor
^ Engine coolant temperature sensor
^ Intake system (vacuum) leaks
^ Low battery charge
^ Spark plugs
The PCM does not monitor either oxygen sensor signal when the engine management system is in open loop or when the purge solenoid is
operating.
If codes other than oxygen sensor codes are present, diagnose/repair these conditions BEFORE continuing with oxygen sensor diagnosis.*
Note:
* A malfunctioning front oxygen sensor may cause fuel trim codes to set.
The scan tool and HDS testing procedures are provided in the following section. The scan tool test is a quick procedure that provides basic sensor
information. The HDS testing procedure requires a more involved set up but provides more detailed information about the sensors performance.
Scan Tool Testing Procedure
Connect the scan tool and retrieve all diagnostic codes. Record the codes and freeze frame data (if available) for later reference.
1. A. Warm up the vehicle to operating temperature (for at least 3 minutes)
B. Select vehicle, year, VIN code, etc.
C. Select "Engine
D. Select "Data"
E. After OBD II data appears press "N"
F. Select "Custom Data List"
G. Select "O2-B1-S1" and "O2-B1-52" (front and rear oxygen sensors) and ENG RPM if no tachometer is available.
H. Press "N" and the selected data will appear
2. While holding the engine speed at 2500 rpm in Neutral or Park (with no load) observe the front and rear oxygen sensors for approximately
one minute. The front oxygen sensor should fluctuate rapidly between 0.095 and 0.995 V. The voltage should read higher than 0.600 V
several times and lower than 0.350 V several times. The voltage should never exceed 1.00 V when using the scan tool.
If an Accent, Elantra or Tiburon front or rear oxygen sensor reads a fixed value of 0.425 V to 0.500 V, or a Sonata reads a fixed value of
0.010 - 0.080 V, check for an open/shorted oxygen sensor circuit or no output from the sensor.
The scan tool can also be used to check the sensors while the vehicle is being driven. An assistant is needed to perform this procedure. Use the scan
tool as set up in the previous test procedure.
both sensors. The sensors should read lean (in the range of 0.20 V down to 0 V) on the scan tool due to the fuel cut-off during deceleration.
scan tool.
Hyundai Diagnostic (HDS) Testing Procedure
The front and rear oxygen sensor signals can be monitored using HDS. The sensor signals can be observed using either "Custom Meters" or "Signal
Wave Forms" on the HDS machine. The "Signal Wave Forms" procedure should be used since the signal resolution is better with the engine at
2500 rpm, which is required for proper testing.
NOTE:
When HDS is used to monitor oxygen sensor signals on 1996 MY and later Accent, Elantra and Tiburon vehicles, a 0.70 V signal offset is
observed. This shifts the sensor readings 0.70 V higher so the new signal range is 0.70 V to 1.70 V. This shift is seen only when using the HDS
machine because the sensor signal is read before it is processed (filtered) by the PCM. The offset has no effect on the sensor signal appearance
or frequency. (See graph.)
1. Connect the scan tool and retrieve all diagnostic codes (see Scan Tool Testing Procedure section for details). If codes other than oxygen
sensor codes are present, diagnose/repair these conditions BEFORE continuing with oxygen sensor diagnosis.
2. Connect HDS to vehicle.
3. Warm up vehicle to operating temperature (until the engine cooling fan begins to cycle, approximately 3 minutes).
4. Select "Signal Wave Forms" from HDS.

5. Select the front and rear oxygen sensor signals and the throttle position sensor (TPS) signal (the TPS is used to establish an approximate
relationship between the throttle position and engine rpm).
6. Select "Digital Record" from the "Options" menu.
7. Select CTRL and set ms/div to 30.00. Click "OK".
8. Select "Run". Run the vehicle at 2500 rpm for several minutes, watch the signal. Record the signal after the engine has stabilized at 2500
rpm. The front oxygen sensor signal should fluctuate quickly (Sonata from 0 to 1.0 V, Accent Elantra & Tiburon from 0.70 to 1.70 V).
9. To view recorded data select 'Options" and 'Data Play Back" and the screen will show the analog form of the recorded data. To use the
Digital Overlay Feature during playback select "CTRL", "Playback", "Digital". Select "Zoom" and "-64" to change the scale to get the 1.92
Sec/Div resolution.
10. The front sensor should cross the midpoint of signal travel at least 7 times in 5 seconds when the vehicle is at 2500 rpm. The rear oxygen
sensor should change slowly, if at all.
11. Record the sensors' reaction to a fuel cut by revving engine to 4000 rpm and let it stabilize. Quickly close the throttle and observe the front
and rear sensor signals (see plots 2 & 5).
Note:
A vacuum leak can also be intentionally created to check sensor response (see plots 3 & 4).
12. If an intermittent condition is reported, "wiggle check" all the connectors and wiring harnesses related to the oxygen sensor while the vehicle
and the HDS are running.
Samples of Oxygen Sensor HDS Plots For Accent, Elantra, Tiberon
^ This sample plot shows a typical front and rear oxygen sensor at 2500 rpm for Accent, Elantra or Tiburon.
^ The front signal is a fluctuating signal that changes from 0.84 to 1.49 V, while the rear signal remains constant. (Note the 0.70 V signal offset).
^ HDS Plot 2 shows a typical Accent, Elantra or Tiburon with the throttle released from 4000 rpm. After a short delay both sensors react and
indicate the mixture is "lean". (Note the 0.70 V signal offset.)
^ HDS Plot 3 shows an Accent, Elantra or Tiburon at 2500 rpm when intentionally introducing a vacuum leak. The front oxygen sensor reacts
lean immediately while the rear reads lean afier a short delay. (Note the 0.70 V signal offset.)
^ Both sensors should always react lean when introducing a vacuum leak unless the vehicle has low mileage or a new catalytic converter.
Samples of Oxygen Sensor HDS Plots For Sonata
^ HDS Plot 4 shows a Sonata V6 at 2500 rpm when introducing a vacuum leak. The front sensor reacts lean immediately while the rear sensor
reads lean after a short delay.
^ Both sensors should always react lean when introducing a vacuum leak unless the vehicle has very low mileage or a new catalytic converter.
^ HDS Plot 5 shows a Sonata V6 at 4000 rpm drop to idle and the front sensor reads lean.
Note 1:
At 4000 rpm the front sensor signal may be rich until the vacuum leak is introduced.
Note 2:
Due to a different engine management system, the rear sensor may not react (lean) as it did with an Accent, Elantra or Tiburon with the same
test (see HDS Plot 2).
^ HDS Plots 6 & 7 show "normal" front and rear oxygen sensor signals for a Sonata V6 at 2500 rpm.
^ During testing the signal may be constant for a period then intermittently have irregular signals (Plot 7). This is normal behavior.
Oxygen Sensor Diagnostic Codes
Oxygen Sensor Diagnostic Codes:
Intermittent malfunctions may be responsible for setting diagnostic codes. A vehicle with an intermittent malfunction may appear to be normal
when the customer brings the vehicle into the dealership. A malfunction must occur in two consecutive trips to illuminate the check engine light,
decreasing the possibility of false codes being set. A test drive, circuit diagnosis and "wiggle check" test may help reveal the condition that is the
cause of the code.
Refer to the 1997 Engine Fault Code Diagnostic Manual, The Shop Manual and Electrical Trouble Shooting Manuals for the specific vehicle wiring
and circuit information.
Oxygen Sensor Installation Tips
^ Be sure to install the oxygen sensors by applying 30 to 45 lb.ft (40.7 to 61.0 Nm) of torque as specified in the Shop Manual for the specific
model.
^ For simplified installation and removal of oxygen sensors, Kent-Moore Tool # J-71 89 and a 22 mm crowsfoot wrench are recommended.
Circuit Diagnosis
^ Oxygen sensor heater resistance should be greater than 30 ohms at 750°F (400°C).
^ Open Circuit:
Disconnect the harness at the PCM and the sensor. Check for continuity in the suspect circuit (example: "A" to "B" from the "Basic O2 Sensor
Circuit" diagram).
^ Short Circuit:
Disconnect the harness at the PCM and the sensor. Check to see if there is continuity to ground in the suspect circuit (example: "A" to ground
from the "Basic O2 Sensor Circuit" diagram).
Engine Fault Code - Diagnostic Manual Correction

Number: 98-36-002
Date: APRIL, 1998
Model: ALL
Subject
1997 ENGINE FAULT CODE DIAGNOSTIC MANUAL (OBD II) CORRECTION

This TSB supersedes TSB # 98-00-001 to include a new category number
DESCRIPTION:
The second step of the Oxygen Sensor Testing Procedure flow chart in the 1997 Engine Fault Code Diagnostic Manual (OBD-II), part no.
NP150-07001, is incorrect. The correct engine RPM is 2500.
Please make the correction to the affected pages noted for future reference.
Affected Pages:
P0130m-3, P0132-3, P0131-3, P0133-4, P0134-3, P0136b-3, P0136m-3, P0137-3, and P0138-3. Technical Service Bulletin # 98-36-003
Date: 980401
Engine Fault Code - Diagnostic Manual Update

Number: 98-36-003
Date: APRIL, 1998
Model: ALL
Subject
1997 FAULT CODE DIAGNOSTIC MANUAL UPDATE (CODE P0125)
DESCRIPTION:
This TSB provides updated information for diagnostic code P0125 (Delayed closed loop operation). A P0125 code may be set by inaccurate
readings from the Engine Coolant Temperature (ECT) sensor or may also be set by an oxygen sensor reading.
Please discard pages P0125-1 and P0125-2 in the 1997 Engine Fault Code Diagnostic Manual (OBD-II), part no. NP150-07001, and insert this
page for future reference. Technical Service Bulletin # 04-00-001 Date: 040501
Engine Controls - O2 Sensor Connector Guidelines

Group: GENERAL
Number: 04-00-001
Date: MAY, 2004
Model: ALL
Subject
GENERAL GUIDELINE FOR 02 SENSOR CONNECTORS
DESCRIPTION:
Most 02 sensors use the wiring/connector for the "reference air" used in determining the 02 signal.
WARNING:
Do not use connector grease on 02 sensor connectors. The grease may cause electrical connection problems. Technical Service Bulletin #
tnt1350903-001 Date: 030901
Engine Controls - Oxygen Sensor Function/Diagnosis

TITLE: Oxygen Sensors
APPLIES TO: 96 - 04 All
SERVICE TIP:
An oxygen sensor measures the amount of oxygen present in the exhaust gas. The oxygen sensor ('element') is coated with a catalyst metal that
produces a small voltage from 0 to 1.00 volt at temperatures in the range of 600°F (315°C) when exposed to oxygen. The "stoichiometric"
air-fuel mixture for optimum fuel economy and emissions occurs at approximately 0.50 V. When the oxygen sensor output signal is above 0.50
V, the air-fuel mixture is considered rich and when the signal is under 0.50 V it is considered lean.
Hyundai OBD II engine management systems (1996 and later models) include two heated oxygen sensors (heated oxygen sensors allow the
vehicle to go into closed loop in 20 to 30 seconds or less to reduce emissions):
^ The "upstream" (front) oxygen sensor is located in the exhaust stream before the catalytic converter. The front sensor provides feedback to
the PCM that is used to identify if the air-fuel mixture supplied to the cylinders is rich or lean. Under normal operating conditions, the front
oxygen sensor signal will fluctuate from 0 to 1.00 V. The front sensor signal should fluctuate, crossing the 0.50 V center about seven times in
5 seconds with the engine held at a steady 2500 rpm, when the vehicle is at operating temperature.
^ The "downstream" (rear) oxygen sensor is located after the catalytic converter in the exhaust stream. The rear sensor provides feedback to the
PCM to 'fine tune' the air-fuel ratio and to monitor catalytic converter efficiency. The rear sensor signal will also fluctuate in the 0 to 1.00V
range but the pattern is less predictable than for the front oxygen sensor because of its position in the exhaust system. Once the catalyst has
reached operating temperature, the rear sensor signal should change very little, if at all. If the rear sensor signal fluctuates at approximately
the frequency of the front sensor, it is an indication that the catalytic converter is not at operating temperature or is malfunctioning.
Oxygen Sensor Diagnosis
A properly operating oxygen sensor may have unusual signal characteristics that are the result of other components. A malfunction of any of the
following components may affect sensor signal characteristics:
^ Fuel injector(s)
^ Air flow sensor
^ Evaporative emission system
^ Barometric pressure sensor
^ Engine coolant temperature sensor
^ Intake system (vacuum) leaks
^ Low battery charge
^ Spark plugs
The PCM does not monitor either oxygen sensor signal when the engine management system is in open loop or when the purge solenoid is
operating.
If codes other than oxygen sensor codes are present, diagnose/repair these conditions BEFORE continuing with oxygen sensor diagnosis.
NOTE: A malfunctioning front oxygen sensor may cause fuel trim codes to set.
^ Several Diagnostic Trouble Codes use specific terminology to refer to sensor location. The illustration and key below explain the following
terms:
^ Engine BANK Bank 1 is closer to the dash panel, (also referred to as RH or right hand). Bank 2 is closer to the radiator, (also referred to as
LH or left hand).
^ UP Refers to Sensor 1 or "front sensor". It is located closer to the exhaust manifold and before the catalytic converter.
^ DOWN Refers to Sensor 2 or "rear sensor." It is located after the catalytic converter.
The following examples show how to interpret oxygen sensor terminology:
B1/S1 = Bank 1/Sensor 1 = Dash panel side, BEFORE the catalyst or "upstream"
B2/S2 = Bank 2/Sensor 2 = Radiator side, AFTER the catalyst or "downstream"
^ The Hi-Scan Pro testing procedure is provided in the following section. The Hi-Scan Pro test is a quick procedure that provides basic sensor
information.
Hi-Scan Pro Testing Procedure
Connect the Hi-Scan Pro and retrieve all diagnostic codes. Record the codes and freeze frame data (if available) for later reference.
1. A. Warm up the vehicle to operating temperature (for at least 3 minutes)
B. Select vehicle, year, etc.
C. Select "Engine"
D. Select "Data"
E. After OBD II data appears press "N"
F. Select "Custom Data"
G. Select "02-B1 S1" and "02-B1 S2" (front and rear oxygen sensors) and ENG RPM if no tachometer is available.
H. Press "N" and the selected data will appear.
2. While holding the engine speed at 2500 rpm in Neutral or Park (with no load) observe the front and rear oxygen sensors for approximately
one minute. The front oxygen sensor should fluctuate rapidly between 0.095 and 0.995 V. The voltage should read higher than 0.600 V
several times and lower than 0.350 V several times. The voltage should never exceed 1.00 V when using the Hi-Scan Pro.
If an Accent, Elantra or Tiburon front or rear oxygen sensor reads a fixed value of 0.425 V to 0.500 V, or a rear oxygen sensor reads a fixed
value of 0.425 V to 0.500 V, or a Sonata reads a fixed value of 0.010 -0.080 V, check for an open/shorted oxygen sensor circuit or no output
from the sensor.
The Hi-Scan Pro can also be used to check the sensors while the vehicle is being driven. An assistant is needed to perform this procedure. Use
the Hi-Scan Pro as set up in the previous test procedure.
both sensors. The sensors should read lean (in the range of 0.20 V down to 0 V) on the Hi-Scan Pro due to the fuel cutoff during
deceleration.
Hi-Scan Pro.
Oxygen sensors can be monitored using HDS. The sensors can be observed using either "Custom Meters" or "Signal Wave Forms" on the HDS
unit. It is preferable to use "signal Wave Forms" since the signal resolution is better with the engine operating at 2500 rpm, which is required for
proper testing.
The HDS testing procedure requires a more involved set up but provides more detailed information about the sensors' performance. Refer to
Technical Service Bulletin #97-36-004 for the testing procedure.
When the HDS is used to monitor oxygen sensor signals on 1996 and 1997 Accent & Elantra and 1997 Tiburon vehicles, a 0.70 V (0.71 V for
Tiburon) signal offset is observed. This shifts the sensor readings 0.70 V (0.71 V for Tiburon) higher so the new signal range is 0.70 V to 1.70 V
(0.71 V to 1.71 V for Tiburon). This shift is seen only when using the HDS machine because the sensor signal is read before it is processed
(filtered) by the engine control module (ECM). (This offset is not present when using the Scan Tool.) The offset has no affect on the sensor
signal appearance or frequency.
The oxygen sensor voltage offset (or bias voltage) observed when using the Hyundai Diagnostic System (HDS) was changed on 1998 Accent,
Elantra & Tiburon from the value of previous model years. The oxygen sensor voltage offset is 0.27 volts for 1998 Elantra and Tiburon, and 0.30
volts for 1998 Accent.
Oxygen Sensor Diagnostic Trouble Codes

The list below contains specific codes for Hyundai oxygen sensors and their explanations as needed.
In addition to further information found in shop manuals, several Technical Service Bulletins have been released regarding oxygen sensors.
These can be found in the TSB bound manual or at the Hyundai Service website "Webtech Pro" section, (login required.)
Keeping up to date on Hyundai oxygen sensor technology will make oxygen sensor diagnosis easier for you.
Brakes - Rear Drum Brake Wheel Cylinder Leak Inspection

Group: CHASSIS
Number: 04-50-010
Model: ALL
Subject
DRUM BRAKE WHEEL CYLINDER BRAKE FLUID
LEAKAGE INSPECTION PROCEDURE
DESCRIPTION:
This bulletin provides the procedure to inspect drum brake wheel cylinders for brake fluid leakage while inspecting the rear brakes.
NOTE:
This bulletin applies to all Hyundai vehicle drum brakes.
SERVICE PROCEDURE:
1. Check the brake fluid level and condition in the master cylinder.
NOTE:
Low brake fluid level or dirty brake fluid indicates a need to perform a thorough inspection of the entire brake system.
2. Start the engine and depress the brake pedal a few times.
3. Shut the engine off and pump the brake pedal a few times, holding it applied for 5 seconds each time.
NOTE:
Observe the brake pedal effort and if the pedal continues to travel after being pushed and held down.
4. Raise and support the vehicle on a hoist.
5. Remove the rear wheels.
6. Remove the brake drum retaining screw from each brake drum.
7. Remove the brake drums.
8. Inspect the drum brake wheel cylinders for brake fluid leak as follows:
A. Brake fluid dripping: If the brake shoes, brake hardware, brake drum, backing plate, etc. are soaked with brake fluid, and if the brake
pedal was observed to continue to travel slowly in step 3, the brake system is leaking and appropriate repair procedures must be
applied to restore the brake system.
B. Brake fluid build-up on and around the wheel cylinders: If dampness and/or a light sheen is observed on and around the brake wheel
cylinders, this condition must be inspected further as follows:
a. Check the wheel cylinder piston for free movement by rocking the shoes or pushing each piston with a screwdriver or a similar
tool.
NOTE:
A seized wheel cylinder piston must be replaced using the appropriate repair procedures provided in the Shop Manuals.
b. Remove the wheel cylinder dust covers using a dull pick or a small screwdriver. If one or more brake fluid drops are observed, it
is a leaking wheel cylinder condition, and must be replaced using the appropriate repair procedures provided in the Shop
Manuals.
c. If no brake fluid leak is observed, reinstall the dust covers and all removed components.
NOTE:
Inspect the other drum brake using the above procedure.
WARRANTY INFORMATION:Technical Service Bulletin # tnt1510205-001 Date: 050201
Brakes - Drum Brake Wheel Cylinder Leakage Inspection

TITLE: Drum Brakes Wheel Cylinder
APPLIES TO: All Hyundai vehicle drum brakes.
SERVICE TIP:
This is the procedure to inspect drum brake wheel cylinders for brake fluid leakage while inspecting the rear brakes.
NOTE: This procedure applies to all Hyundai vehicle drum brakes.
SERVICE PROCEDURE:
1. Check the brake fluid level and condition in the master cylinder.
NOTE: Low brake fluid level or dirty brake fluid indicates a need to perform a thorough inspection of the entire brake system.
2. Start the engine and depress the brake pedal a few times.
3. Shut the engine off and pump the brake pedal a few times, holding it applied for 5 seconds each time.
NOTE: Observe the brake pedal effort and if the pedal continues to travel after being pushed and held down.
4. Raise and support the vehicle on a hoist.
5. Remove the rear wheels.
6. Remove the brake drum retaining screw from each brake drum.
7. Remove the brake drums.
8. Inspect the drum brake wheel cylinders for brake fluid leak as follows:
A. Brake fluid dripping: If the brake shoes, brake hardware, brake drum, backing plate, etc. are soaked with brake fluid, and if the brake
pedal was observed to continue to travel slowly in step 3, the brake system is leaking and appropriate repair procedures must be applied
to restore the brake system.
B. Brake fluid build-up on and around the wheel cylinders: If dampness and/or a light sheen is observed on and around the brake wheel
cylinders, this condition must be inspected further as follows:
a. Check the wheel cylinder piston for free movement by rocking the shoes or pushing each piston with a screwdriver or a similar tool.
NOTE: A seized wheel cylinder piston must be replaced using the appropriate repair procedures provided in the Shop Manuals.
b. Remove the wheel cylinder dust covers using a dull pick or a small screwdriver. If one or more brake fluid drops are observed, it is a
leaking wheel cylinder condition, and must be replaced using the appropriate repair procedures provided in the Shop Manuals.
c. If no brake fluid leak is observed, reinstall the dust covers and all removed components.
NOTE: Inspect the other drum brake using the above procedure.
Battery - Cover/Insulation Pad Applications/Installation

Group
Number
03-36-022
Date
November, 2003
Model
Santa Fe 2001-2004, Sonata 1989-2004, XG 300 2001 and XG 350 2002-2004
Subject
BATTERY COVER INFORMATION
This TSB updates and combines information previously released in TSB # 03-36-005 and TSB # 03-36-009.
DESCRIPTION:
A battery cover (insulation pad, glass wool) is installed on Sonata, Santa Fe and XG 350 vehicles to extend the battery life.
CAUTION
Do not discard the battery cover after service that requires battery removal. The battery cover must be reinstalled after service to ensure longer
battery life. The battery cover protects the battery from engine heat.
VEHICLES AFFECTED
NOTE
If a Hyundai supplied replacement battery is to be installed, install the battery cover before installing the battery (the battery cover will not fit
when installed after the battery has been installed).
NOTE
The above picture illustrates the issue for the Santa Fe, as an example. The "Insulation Pad" part numbers for the other models are shown in this
TSB.
OLDER VEHICLES EQUIPPED WITH PLASTIC BATTERY COVER:
Some older vehicles may have been originally equipped with a Plastic Cover over the battery. If so, when replacing the battery, discard the Plastic
Cover and install the new Glass Wool type of Insulation Pad (the appropriate part number is shown).
PARTS INFORMATION
Battery - Maintenance/Charging/Diagnostics/Replacement
Group:
ENGINE ELECTRICAL
Number:
05-36-011
Date:
NOVEMBER, 2005
Model:
ALL
Subject
BATTERY MAINTENANCE, DIAGNOSTIC, CHARGING, REPLACEMENT AND WARRANTY INFORMATION PROCEDURES
DESCRIPTION:
As the demands on vehicle batteries increase with the complexity of electrical systems, it is important to follow a consistent and repeatable
procedure for battery maintenance, diagnosis, charging and replacement.
SAFETY PRECAUTIONS:
^ Always wear safety glasses and rubber gloves when handling a battery.
^ A cracked or damaged battery can emit hydrogen gas, which can cause skin burn and risk of fire or explosion.
^ Charge the battery in a well ventilated area.
^ Prevent short-circuiting and/or emission of sparks around the battery.
^ Do not tilt a battery.
^ Do not exert force of any kind on a battery.
^ Keep batteries away from flammable areas and objects.
^ Do not quick charge a battery unless suggested by the battery charging procedure.
^ Keep batteries away from high temperature and humidity.
^ Store batteries in a cool place and away from rain, snow and direct sunlight.
^ Dispose batteries by following environmentally established battery disposal procedures.
SERVICE PROCEDURE:
Battery in vehicle:
The following procedure is recommended when storing vehicles for extended periods of time.
^ Remove/Pull the memory fuse at the junction box to prevent quick battery discharging.
^ Run the engine at least once a month to recharge the battery, as necessary.
^ Immediately prior to delivery, the vehicle battery should be checked and charged as necessary (no battery replacement should be attempted until
the battery has been checked using the battery diagnostic, charging and replacement procedure provided in this bulletin).
NOTE:
It is the Dealer's responsibility to determine the condition/chargeability of a battery prior to replacement of the battery.
Battery on shelf:
^ Batteries should be stored in a cool, dry place and out of direct sunlight.
^ Maintenance Free (MF) batteries are tightly sealed to prevent acid leakage; however, tilting them at an angle greater than 45 degrees may cause
acid leakage through the vents on the sides.
^ Always store batteries in their upright position.
^ Prevent placing any solid conducting bodies on top of a battery.
^ It is extremely dangerous to use tools, such as hammers, on the battery terminals when connecting cables to the mounted battery.
Battery diagnostic, charging and replacement procedure.
Normal warranty procedures apply.

^ Please see Section 6 - Warranty Retention Administrative Requirements in your current Policy and Procedures manual.
^ Please see Section 3 - New Vehicle Preparation and Delivery in your current Policy and Procedures manual.
Technical Service Bulletin # NHTSA00V314000 Date: 000925
Recall 00V314000: Possible Fuel tank Leak & MIL ON

Accent GT model vehicles equipped with DOHC engines manufactured from December 19, 1996 through June 30, 1997; 1998 Accent model
vehicles manufactured from May 6, 1997 through June 25, 1998; 1997 Sonata vehicles manufactured from August 1, 1996 through July 9, 1997
and 1998 Sonata vehicles produced from July 9, 1997 through April 24, 1998. The evaporative emission control systems may apply excessive
vacuum to the fuel tanks during the canister purge cycle. Minor fuel tank distortion could result. A small crack could develop on the upper fuel tank
surface. The "Check Engine" light would then illuminate and, in some cases, the vehicle driver could notice a gasoline odor.
Fuel leakage in the presence of an ignition source can result in a fire.
Dealers will pressure check the vehicle's fuel tank to determine if it has cracked. If it is cracked, a new fuel tank will be installed. A new fuel filler
cap that decreases the amount of vacuum inside the fuel tank will also be installed.
The 1997-1998 Sonata fuel tanks have also experienced cracking. However, at this time, the cause for the cracking has not been identified. This
portion of the campaign will begin after Hyundai has determined the cause and corrective procedure.
Owner notification is expected to begin during January 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service
date and do not receive the free remedy within a reasonable time should contact Hyundai at 1-800-829-9956. Also contact the National Highway
Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Technical Service Bulletin # 01-01-004-1
Date: 010401
Recall - Canister Air Intake/Fuel Tank Replacement

Group: CAMPAIGN BULLETINS
Number: 01-01-004-01
Date: APRIL, 2001
Model: 1997-98 SONATA
Subject:
1997-98 SONATA CANISTER AIR INTAKE REPLACEMENT AND FUEL TANK INSPECTION CAMPAIGN 044
This TSB has been revised to add an "A" assembly plant VIN identifier and make several minor changes to the procedure.
DESCRIPTION
Some 1997 and 1998 SONATA vehicles may experience excessive vacuum formation in the fuel tank caused by contamination of the canister air
filter. This may cause minor distortion of the fuel tank. After prolonged exposure to the excessive vacuum, a small crack may develop on the upper
fuel tank.
A new canister air intake system has been made available to prevent this contamination condition. Inspect the fuel tank for cracking by using the
following procedure and replace the canister air filter with the new canister air intake system.
VEHICLES AFFECTED
^ Sonata:
- 1997 Model Year: All models
- 1998 Model Year: 2.0 Liter DOHC Federal specification vehicles only.
^ Affected VIN:
PARTS REQUIRED
Service Procedure
FUEL TANK INSPECTION
1. Lift the vehicle on a hoist.
2. Locate the canister behind the left rear wheel of the vehicle and disconnect the fuel vapor hose to fuel tank hose clamp.
3. Connect the Low Pressure EVAP Tester (KENT MOORE/SPX EVAP Tester P/N J-44680) to the disconnected fuel vapor hose.
NOTES:
^ Select correct size hose barb fitting for the tool based on the inner diameter of the hose and install the proper size of hose barb onto the low
pressure tester using teflon tape (or equivalent) to insure a good seal.
^ Slide the hose clamp over the barb connector to prevent any leaks.
4. Using a Mityvac pump (Snap-On P/N YA4000 or equivalent), connect the pump to the one-way valve in the low pressure gauge and then
pump the system until the low pressure gauge reads 20 inches H20.
NOTES:
^ 1 inch H20 = 0.036 psi
20 inches H20 = 0.72 psi
^ The low pressure gauge is a very sensitive tool. Do not exceed 30 inches H20 (1.08 psi) when pressurizing the system (pressurize slowly!)
or the gauge will be damaged.
^ Never use shop air.
^ Never pressurize the low pressure gauge by itself.
^ Slowly pressurize system up to 20 inches H20. Use the bleeder valve to bleed off pressure if over 20 inches H20 and allow 30 seconds for
the system to settle. The system will "settle" (drop 3-7 inches H20) over a short period of time to equalize pressure throughout the system.
Repressurize the system with the Mityvac pump up to a pressure of 20 inches H20 after "settling" has stabilized. Monitor the gauge for two
minutes.
5. Monitor the pressure gauge for two minutes.
A1. If the gauge remains steady or drops less than 2 inches H20 (0.072 psi) in two minutes, the fuel tank does not require replacement.
A2. Reconnect the disconnected canister-to-fuel tank hose.
A3. Continue at step 10.
B1. If the gauge drops more than 2 inches H20 (0.072 psi) in two minutes, a small leak is present.
B2. Continue at Step 6
6. Diagnose the fuel filler neck first for a small leak by performing all of the following:
A. Swapping fuel caps with a known good fuel cap and repeating Steps 4 and 5.
B. Remove the left rear wheel, pressurize the system to 20 inches H20 and squirt the filler neck pipe area with soapy water. If no leak is
found, continue to Step 7.
C. If a leak is found in the filler cap/neck area, repair and continue at Step 9.
7. Remove the fuel tank from the vehicle and inspect the rollover valve and fuel line hoses for signs of leakage. If there are no signs of leakage,
continue at Step 8.
8. Replace the fuel tank with P/N 31150-34Q70, which includes the pads. Attach the pads in the locations shown with 3M(TM) Super 77 Spray
Adhesive (or equivalent).
9. Transfer the fuel shut-off valve, rollover valve, and heat shield to the new fuel tank.
10. After any necessary repairs have been made, reassemble the evaporative system and repeat Steps 4 and 5 to verify the repair.
AIR INTAKE SYSTEM HOSE REPLACEMENT
11. Remove the air filter and hose that connects the air filter to the 2-way valve and discard them.
12. Connect the straight end (without the grommet) of the supplied hose (P/N 31377-34Q70) to the 2-way valve and secure with a hose clamp.
Insert the other end of the hose into the left rear side member (frame rail) as shown. Plug the grommet into the hole in the side member. Tie
the middle of the hose to the fuel vapor hoses with a tie strap (P/N 17993-19000 or equivalent).
NOTE:
The hose end inserted into the side member hole should face toward the rear of the vehicle.
FUEL TANK REPLACEMENT

When installing the new fuel tank, tighten the self-locking nuts until the end of each looped fuel tank mounting band touches the vehicle underbody
or the gap between the band and the underbody surface is .35-.43" (9-11 mm) as shown on the illustration.
1997 SONATA; 1998 2.0L Federal Spec Only:
EVAPORATIVE EMISSION SYSTEM SCHEMATIC

CAMPAIGN CLAIM INFORMATION
NOTE:
Submit claims using the campaign claim screen.
Technical Service Bulletin # NHTSA00V314001 Date: 001025
Recall 00V314001: Fuel Tank/Evaporative System Defect

Defect Summary:
VEHICLE DESCRIPTION: ACCENT GT MODEL VEHICLES EQUIPPED WITH DOHC ENGINES MANUFACTURED FROM DECEMBER
19, 1996 THROUGH JUNE 30, 1997; 1998 ACCENT MODEL VEHICLES MANUFACTURED FROM MAY 6, 1997 THROUGH JUNE 25,
1998; 1997 SONATA VEHICLES MANUFACTURED FROM AUGUST 1, 1996 THROUGH JULY 9, 1997 AND 1998 SONATA VEHICLES
PRODUCED FROM JULY 9, 1997 THROUGH APRIL 24, 1998. THE EVAPORATIVE EMISSION CONTROL SYSTEMS MAY APPLY
EXCESSIVE VACUUM TO THE FUEL TANKS DURING THE CANISTER PURGE CYCLE. MINOR FUEL TANK DISTORTION COULD
RESULT. A SMALL CRACK COULD DEVELOP ON THE UPPER FUEL TANK SURFACE. THE "CHECK ENGINE" LIGHT WOULD
THEN ILLUMINATE AND, IN SOME CASES, THE VEHICLE DRIVER COULD NOTICE A GASOLINE ODOR.
Consequence Summary:
FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Corrective Summary:
DEALERS WILL PRESSURE CHECK THE VEHICLE'S FUEL TANK TO DETERMINE IF IT HAS CRACKED. IF IT IS CRACKED, A NEW
FUEL TANK WILL BE INSTALLED. A NEW FUEL FILLER CAP THAT DECREASES THE AMOUNT OF VACUUM INSIDE THE FUEL
TANK WILL ALSO BE INSTALLED. Technical Service Bulletin # 00-40-010 Date: 000801
A/T - MIL ON DTCs P0712/P0713 Set

Group:
TRANSAXLE
Number:
00-40-010
Date:
AUGUST, 2000
Model:
ALL
Subject:
AUTOMATIC TRANSAXLE OIL TEMPERATURE SENSOR DIAGNOSIS
DESCRIPTION:
An automatic transaxle oil temperature sensor with an OPEN circuit may result in the following symptoms:
^ Harsh P-R or P-D engagement
^ No 4th gear engagement (1996-2000 Elantra & Tiburon1 1995-2001 Accent)
^ 2nd Gear Hold (1999-2001 Sonata)
^ Damper clutch not engaged
^ MIL illuminated
^ Diagnostic Trouble Code: P0713 - Fluid temperature sensor - open circuit
An automatic transaxle oil temperature sensor with a SHORT circuit may result in the following symptoms:
^ 2-3 shift flare (Accent, Elantra, Tiburon)
^ MIL illuminated
^ Diagnostic Trouble Code: P0712 - Fluid temperature sensor - short circuit
If you are servicing a vehicle with these symptoms, please apply the following Repair
Procedure.
REPAIR PROCEDURE:
1. Disconnect the connectors between the oil temperature sensor and TCM. Check for bent pins or pins not fully inserted in the connector.
Repair as necessary
2. Measure the resistance of the harness between the sensor connector and TCM connector. Refer to the appropriate ETM to find the correct pin
terminals. If the resistance is:
^ More than 1 ohm: Repair the harness
^ Less than 1 ohm: Go to Step 3.
3. Attach a Hi-Scan Pro to the Data Link Connector (DLC) and select: "Hyundai Vehicle Diagnosis" menu, "Automatic Transaxle" menu and
"Diagnostic Trouble Codes". It the readout indicates:
^ DTC P0712 or P0713 - Replace the oil temperature sensor
^ No DTC-gotostep4
4. With the Hi-Scan Pro attached to the Data Link Connector, select: "Hyundai Vehicle Diagnosis" menu, "Automatic Transaxle" menu,
"Current Data" menu and "Temperature Sensor". Check "Temperature Sensor" when the ATF is cold and hot. The oil temperature sensor is
operating correctly if the readout is:
5. If the temperature sensor does not read as in Step 4, replace the oil temperature sensor.
PARTS INFORMATION:
A/T - DTC's P0731/P0732/P0733/P0734/P0735/P0736

Group: TRANSAXLE
Number: 03-40-005
Date: APRIL, 2003
Model: ALL
Subject
AUTOMATIC TRANSAXLE DIAGNOSTIC TROUBLE CODES P0731, P0732, P0733, P0734, P0735, P0736
DESCRIPTION:
The following diagnostic trouble codes (DTC) indicate the transaxle control module (TCM) detected clutch slippage of more than 200 rpm. If you
are servicing a vehicle with one or more of the following DTCs, go to "Repair Procedure".
REPAIR PROCEDURE:
1. Check for either of the following DTCs in the "Automatic Transaxle" menu:
^ If so, repair according to the procedure in the TSB listed.
^ If not, go to Step 2.
2. Record the exact customer comment. Delete the DTC. Perform the following tests, then follow the "Repair Procedure" shown below:
^ Attach the A/T Tester and place the transaxle shift lever in "D".
^ Move the gear selector switch of the A/T Tester to 1, 2, 3, 4 and 5 (if equipped) and perform a stall test in each gear.
^ Use EF.XG knob for 1999~ Sonata, 2001~ Elantra, Santa Fe & XG, 2003~ Tiburon
^ Use LC knob for 1999~ Accent, 1999-2000 Elantra & 1999-2002 Tiburon
^ Refer to the appropriate shop manual for stall test specifications.

^ Disconnect the A/T Tester. Delete any solenoid DTC induced by the A/T Tester.
^ Test drive the vehicle for two key-on to key-off driving cycles when the ATF is hot (above 158°F or 70° C). Drive the vehicle under similar
conditions as reported by the customer. Perform several 1-2-3-4 upshifts and 4-3-2-1 downshifts. Repair as shown. Technical Service
Bulletin # 05-40-016 Date: 051001
A/T - No Movement in 'DRIVE' or 'REVERSE'

Group: TRANSAXLE
Number: 05-40-016
Date: OCTOBER, 2005
Model: ALL
Subject:
AUTOMATIC TRANSAXLE - NO MOVEMENT IN DRIVE OR
REVERSE GEAR
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DIG are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide conclusive results, remove the oil pan and
check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not replace the transaxle. SPIII may change color to
a dark brown after 10,000 to 25,000 miles in service. This change is normal for this type of ATF.
VERIFY THE RANGE SWITCH ADJUSTMENT:

3. Move the shift lever to "N".
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the drill or bolt fits into the adjustment holes.
^ If so, go to step 9
5. Loosen the two 10 mm mounting bolts.
6. Disconnect the shift cable at the lever.
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two 10 mm mounting bolts to specification.
Specification: 7-8 ft.lb (10-12 Nm, 100-120 kg.cm)
8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut. Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
Remove the 5 mm drill or M5 bolt.
VERIFY THE SIGNAL FROM THE RANGE SWITCH:
9. Attach a Hi-Scan Pro and select:
^ "Hyundai Vehicle Diagnosis"
^ Vehicle
^ "Automatic Transaxle" menu

^ "Current Data" menu
^ "Select Lever Switch" and "Shift Position":
10. Move the shift lever to Reverse.
^ Monitor "Select Lever Switch".
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully inserted. Check the wiring harness for an open
or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
Monitor "Shift Position" and "Select Lever Switch".
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch. Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully inserted. Check the wiring harness for an open
or short circuit. If ok, replace the range switch.
12. Install the A/T Tester, P/N 09450-AT000, to the vehicle:
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1, 2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the solenoid. Shift the transaxle to "R".
^ If no movement, replace the transaxle.
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or pin not fully inserted. Check the wiring
harness for an open or short circuit.
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and Reverse. If the vehicle moves in Drive and
Reverse, replace the TCM.
Applicable Warranty Applies.Technical Service Bulletin # 03-90-001 Date: 030201
Audio System - Clicking Noise From Speakers

Group: BODY ELECTRICAL
Number: 03-90-001
Model: ALL
Subject
CLICKING NOISE FROM RADIO SPEAKERS
CAUSED BY WIRELESS TELEPHONE
RADIO FREQUENCY INTERFERENCE
DESCRIPTION:
Some vehicles may experience an intermittent, faint clicking sound from the radio speakers. The noise may be described as either a clicking or
popping sound from the dash area. This sound may be caused by radio frequency (RF) signals emitted by the vehicle occupant is wireless phone.
Wireless telephones are hand-held phones with built-in antennas, often called cell, mobile or PCS phones. Wireless telephones are two-way radios.
When a person speaks into a wireless telephone, it picks up the person's voice and converts the sound to radio frequency energy (or radio waves).
The radio waves travel through the air until they reach a receiver at a nearby base station. The base station then sends the call through the telephone
network until it reaches the person you are calling.
When a person receives a call on his/her wireless telephone, the message travels through the telephone network until it reaches a base station close
to his/her wireless phone. Then the base station sends out radio waves that are detected by a receiver in his/her telephone, where the signals are
changed back into the sound of a voice.
Radio frequency energy from wireless phones can be picked up by electronic devices in the car such as:
^ Radio Receiver
^ Radio speakers
^ External amplifiers (if equipped)
Some wireless telephone providers require the phone to check into nearby base stations periodically for voice mail messages and reception signals.
In addition, it informs the cell site if the phone is in range.
The occupant may hear a clicking noise from the speakers when the following occurs:
^ The occupant is making a call
^ The occupant receives a call
^ The wireless phone is checking into a nearby base station
^ The wireless phone changes cell sites
Hyundai radios are designed to comply with Federal Communication Commission (FCC) rules, which state operation is subject to the following
condition:
^ This device (radio receiver) may not cause harmful interference
^ This device must accept any interference received, including interference that may cause undesired operation
To minimize the interference of the radio receiver:
^ Reorient or relocate the wireless phone (increase the separation between the wireless phone and the radio receiver/speakers/external amplifiers)
^ This condition varies, depending on the wireless phone make and model, service provider and geographical area
^ Drive with the wireless phone off to see if the clicking occurs Technical Service Bulletin # 01-90-013 Date: 011101
Restraint System - Component Replacement After Collision

Group
90 - ELECTRICAL
Number
01-90-013
Date
11-2001
Model
All Models
Subject
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) REPAIR AFTER COLLISION
DESCRIPTION:
This TSB describes the components that must be replaced after the deployment of an SRS component.
COMPONENT REPLACEMENT TABLE
WARNING
Failure to replace all of the parts listed may affect operation of the supplemental restraint system (SRS) operation in the event of a subsequent
accident.
^ Collision repair is not covered under warranty.

Airbags - Replacement After A Collision

Group
90 - ELECTRICAL
Number
04-90-002
Date
01-2004
Model
ACCENT 1995-2002, ELANTRA 1992-2003, EXCEL 1986-1994, SANTA FE 2001-2004, SCOUPE 1991-1995, SONATA 1989-2004,
TIBURON 1997-2004, XG 300 2001 AND XG 350 2002-2004
Subject
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) REPAIR AFTER COLLISION
This bulletin supersedes TSB # 03-90-023 to include additional Airbag Wire Harness information.
DESCRIPTION:
This TSB describes the components that must be replaced after the deployment of an SRS component.
COMPONENT REPLACEMENT TABLE
WARNING
Failure to replace all of the parts listed may affect operation of the supplemental restraint system (SRS) operation in the event of a subsequent
accident.
Collision repair is not covered under warranty.

Airbag Repair Kit - Part Number Update

Number: 98-90-005
Date: MARCH, 1998
Model: ALL ACCENT & TIBURON

1994-98 ELANTRA & 1995-98 SONATA
Subject
AIRBAG REPAIR KIT PART NUMBERS
This TSB revises TSB # 97-90-003, and contains updated part number information.
DESCRIPTION:
When repairing a Hyundai vehicle that has been involved in an accident where the airbags have deployed, the following components must be
replaced:
1) Deployed airbags
2) Airbag control module assembly (computer)
3) Airbag control module assembly machine screws
4) Clock spring contact assembly
5) Airbag wiring harness
Hyundai has developed airbag repair kits to assist dealers when replacing all of these components. The airbag repair kits include items 2-5 as listed.
Failure to replace all of the parts listed may adversely affect the supplemental restraint system (SRS) in the event of a subsequent accident.
In addition to ordering the airbags (which are color specific), an airbag repair kit should also be ordered. The part numbers for these kits are listed:
- Warranty coverage does not apply to complete repair kit.
- Please note that all airbags replaced under warranty will be requested for return to Hyundai's Warranty Technical Center (WTC).
Recall - Canister Air Filter Replacement

Group: CAMPAIGN BULLETINS
Number: 01-01-004
Date: MARCH, 2001
Model: 1997-98 SONATA

Subject:
1997-98 SONATA CANISTER AIR INTAKE
REPLACEMENT AND FUEL TANK INSPECTION
CAMPAIGN 044
DESCRIPTION:
Some 1997 and 1998 SONATA vehicles may experience excessive vacuum formation in the fuel tank caused by contamination of the canister air
filter. This may cause minor distortion of the fuel tank. After prolonged exposure to the excessive vacuum, a small crack may develop on the upper
fuel tank.
A new canister air intake system has been made available to prevent this contamination condition. Inspect the fuel tank for cracking by using the
following procedure and replace the canister air filter with the new canister air intake system.
VEHICLES AFFECTED
^ Sonata:
- 1997 Model Year: All models
- 1998 Model Year: 2.0 Liter DOHC Federal specification vehicles only.
^ Affected VIN:
2.0 Liter 1997 KMHCF_4F _ VU_ _ _ _ _ _..........(CA and Federal)
3.0 Liter 1997 KMHCF_4T _ VU_ _ _ _ _ _..........(CA and Federal)
2.0 Liter 1998 KMHCF_4F _ WU_ _ _ _ _ _..........(Federal Only)

PARTS REQUIRED:
1997 SONATA; 1998 2.0L Federal Spec Only:

EVAPORATIVE EMISSION SYSTEM SCHEMATIC
CAMPAIGN CLAIM INFORMATION:
NOTE:
Submit claims using the campaign claim screen.
Service Procedure
FUEL TANK INSPECTION
1. Lift the vehicle on a hoist.

2. Locate the canister behind the left rear wheel of the vehicle and disconnect the fuel vapor hose to fuel tank hose clamp.
3. Connect the Low Pressure EVAP Tester (KENT MOORE/SPX EVAP Tester P/N J-44680) to the disconnected fuel vapor hose.
NOTES:
^ Select correct size hose barb fitting for the tool based on the inner diameter of the hose and install the proper size of hose barb onto the low
pressure tester using teflon tape (or equivalent) to insure a good seal.
^ Slide the hose clamp over the barb connector to prevent any leaks.
4. Using a Mityvac pump (Snap-On P/N YA4000 or equivalent), connect the pump to the one-way valve in the low pressure gauge and then
pump the system until the low pressure gauge reads 20 inches H20.
NOTES:
^ 1 inch H20 = 0.036 psi
^ The low pressure gauge is a very sensitive tool. Do not exceed 30 inches H20 (1.08 psi) when pressurizing the system (pressurize slowly!)
or the gauge will be damaged.
^ Never use shop air.
^ Never pressurize the low pressure gauge by itself.
^ Slowly pressurize system up to 20 inches H20. Use the bleeder valve to bleed off pressure if over 20 inches H20 and allow 30 seconds for
the system to settle. The system will "settle" (drop 3-7 inches H20) over a short period of time to equalize pressure throughout the system.
Repressurize the system with the Mityvac pump up to a pressure of 20 inches H20 after "settling" has stabilized. Monitor the gauge for two
minutes.
5. Monitor the pressure gauge for two minutes.
A1. If the gauge remains steady or drops less than 2 inches H20 (0.072 psi) in two minutes, the fuel tank does not require replacement.
A2. Reconnect the disconnected canister-to-fuel tank hose.
A3. Continue at step 10.
B1. If the gauge drops more than 2 inches H20 (0.072 psi) in two minutes, a small leak is present.
B2. Continue at Step 6
6. Diagnose the fuel filler neck first for a small leak by performing all of the following:
A. Swapping fuel caps with a known good fuel cap and repeating Steps 4 and 5.
B. Remove the left rear wheel, pressurize the system to 20 inches H20 and squirt the filler neck pipe area with soapy water. If no leak is
found, continue to Step 7.
C. If a leak is found in the filler cap/neck area, repair and continue at Step 9.
7. Remove the fuel lank from the vehicle and inspect the rollover valve and fuel line hoses for signs of leakage. If there are no signs of leakage,
continue at Step 8.
8. Replace the fuel tank with P/N 31150-34Q70, which already has the pads attached to the upper fuel tank, after transfering the fuel shut-off
valve, rollover valve and heat shield to the new fuel tank.
9. After any necessary repairs have been made, reassemble the evaporative system and repeat Steps 4 and 5 to verify the repair.
AIR INTAKE SYSTEM HOSE REPLACEMENT
10. Remove the air filter and hose that connects the air filter to the 2-way valve and discard them.
11. Connect the straight end (without the grommet) of the supplied hose (P/N 31377-34Q70) to the 2-way valve and secure with a hose clamp.
Insert the other end of the hose into the left rear side member (frame rail) as shown. Plug the grommet into the hole in the side member. Tie
the middle of the hose to the fuel vapor hoses with a tie strap.
NOTE:
The hose end inserted into the side member hole should face toward the rear of the vehicle.
FUEL TANK REPLACEMENT
NOTE:
When installing the new fuel tank, tighten the self-locking nuts until the end of each looped fuel tank mounting band touches the vehicle
underbody or the gap between the band and the underbody surface is .35-.43" (9-11 mm) as shown on the illustration.
Engine - Oil Filter Information/Applications

Group
20 - ENGINE MECHANICAL
Number
04-20-001
Date
01-2004
Model
ACCENT 1995-2004, ELANTRA 1992-2004 EXCEL 1986-1994 SANTA FE 2001-2004, SCOUPE 1991-1995 SONATA 1989-2004 TIBURON
1997-2004 XG, 300 2001 AND XG 350 2002-2004
Subject
ENGINE OIL FILTER INFORMATION
DESCRIPTION:
The engine oil filter has been superseded from part number 26300-35500 to part number 26300-35501. This oil filter is currently used on all
Hyundai models.
The change is cosmetic, to include the words Kia Motors, the Kia logo and the new part number. Form, fit and function have not been affected.
To insure proper filtration of the lubrication system, only Hyundai Genuine Parts should be installed by a Hyundai approved facility. Damage
resulting from parts other than Hyundai Genuine Parts may not be covered under warranty.
Engine - Knocking Noise When Using Non-OE Oil Filter

Group: ENGINE MECHANICAL
Number: 05-20-002
Date: JULY, 2005
Model: ALL MODELS
Subject:
USE OF AFTERMARKET ENGINE OIL FILTERS
CAUSING ENGINE KNOCKING NOISE
DESCRIPTION:
Some vehicles may experience an engine knock noise with the use of an aftermarket oil filter. Aftermarket oil filters may use different materials,
construction and specifications than genuine Hyundai oil filters, which may lead to pressure variations within the engine, thus contributing to an
engine knocking noise.
VEHICLES AFFECTED:
All Models
REPAIR PROCEDURE:
Perform an oil change on the vehicle and replace the aftermarket oil filter with a genuine Hyundai oil filter.
Normal warranty procedures apply.
This is not a warranty repair.
Brake Rotor - Surface Rust Noise & Pedal Pulsation.

Group:
CHASSIS
Number:
99-50-011
Date:
DECEMBER, 1999
Model:
ALL
Subject:
BRAKE ROTOR SURFACE RUST NOISE AND BRAKE PEDAL PULSATION
DESCRIPTION:
Surface rust on the brake rotors may occur if a vehicle has been parked for several days in an area where corrosive conditions were present. If the
rotor surface does rust, the area under the brake pads usually remains rust free. The difference in friction between the rusted and unrusted areas may
induce slight brake pedal pulsation, vibration and/or noise for several stops, but will improve as the brake pad friction linings polish the rust off the
rotor.
Typically, three or four stops will polish the rotor surfaces.
If customers inquire about this condition, it may be explained as a normal occurrence. It does not affect brake performance.
Front Brake Disc - Machining Recommendations

Group: CHASSIS
Number: 97-50-007
Model: ALL
Subject
FRONT BRAKE DISC MACHINING RECOMMENDATIONS
PURPOSE:
This service bulletin provides front brake disc machining recommendations and procedures to reduce the disc thickness variation that may cause
brake pedal pulsation.
DESCRIPTION:
Hyundai vehicles use two methods of attaching front brake discs. On Excel, Scoupe, Accent, Elantra and Tiburon models, the disc is attached on
the inside of the hub assembly making it less efficient to remove for machining (see illustration). On Sonata models, the disc is attached on the
outside of the hub assembly making it very easy to remove for machining (see illustration).
The following Service Procedures contain front brake disc machining recommendations and procedures for both types of disc attachment methods.
SERVICE PROCEDURE 1 (All models):
Machining of brake discs using an "on-car lathe" is recommended for ALL Hyundai models. An "on-car lathe" provides efficiency and accuracy as
it machines the disc true to the hub's center of rotation. Use an "on-car lathe" made by PRO-CUT (models CROS 700 or PFM 900) or equivalent,
and always follow the lathe manufacturer's instructions for properly machining the brake disc.
SERVICE PROCEDURE 2:
Service Procedure 2 is recommended only if Service Procedure 1 is not available.
^ For the "Inside of Hub" disc attachment design (used on Excel, Scoupe, Accent, Elantra & Tiburon models), follow the steps outlined in Service
Procedure 2A.
^ For the "Outside of Hub" disc attachment design (used on Sonata model only), follow the steps outlined in Service Procedure 2B.
Service Procedure 2A (Excel Scoupe Accent Elantra & Tiburon):
Use the following steps to machine an "Inside of Hub" disc attachment design:
1. Confirm that the "off-car lathe" has a spindle arm holding fixture.
Note:
If your "off-car lathe" doesn't have the spindle arm fixture, use Service Procedure 3 for machining the disc.
2. Remove hub and knuckle assembly from the vehicle per procedure outlined in the appropriate Shop Manual.
Note:
Do not use a "slide hammer" to remove the hub assembly. This may damage the wheel bearings.
3. Mount the knuckle assembly with the disc on the "off-car lathe" (see illustration above).
4. Machine the disc on the "off-car lathe" following the lathe manufacturer's instructions. (See appropriate Shop Manual for service limit
specification.)
5. Reinstall the hub and knuckle assembly on the vehicle.
6. Repeat procedure for other side.
Service Procedure 2B (Sonata model):
Use the following steps to machine an "Outside of Hub" disc attachment design.
1. Remove the disc from the vehicle per procedure outlined in the appropriate Shop Manual.
2. Mount the disc on the "off-car lathe".
3. Machine the disc on the "off-car lathe" following the lathe manufacturer's instructions. (See appropriate Shop Manual for service limit
specification.)
4. Reinstall the disc on the vehicle.
SERVICE PROCEDURE 3 (Excel, Scoupe, Accent, Elantra & Tiburon):
Note:
Use Service Procedure 3 ONLY if Service Procedures 1 & 2A are not available.
1. Remove hub and knuckle assembly from the vehicle per procedure outlined in the appropriate Shop Manual.
2. Separate disc from knuckle and hub assembly per procedure outlined in the appropriate Shop Manual.
Note:
Do not use a "slide hammer" to remove the hub assembly from the knuckle assembly. This procedure may damage the wheel bearings.
3. Machine the disc on the off-car lathe following the lathe manufacturer's instructions.
4. Reinstall the disc on the hub and knuckle assembly.
5. Reinstall the hub and knuckle assembly on the vehicle.
Head & Tail Lamp - Cleaning Procedure

Number
00-60-001
Group
BODY
Date
MARCH, 2000
Subject
HEAD AND TAIL LAMP CLEANING INFORMATION
Model
ALL
DESCRIPTION:
This bulletin provides information about how to correctly clean Hyundai head and tail lamps. It is recommended that dealership personnel and
customers not use solvents such as paint thinner, gasoline or corrosive solvent when removing accumulated dust or stains on the lamps.
TO CLEAN HEAD LAMPS:
1. To clean head lamps and tail lamps, wash them with a mild auto body shampoo and water. Completely wet the lamp before wiping to prevent
the dirt from scratching the plastic.
2. If the lens surface becomes scratched, use a fine auto body polishing compound and a rotary buffer to polish out the scratches.
- Use a clearcoat compatable polishing compound
- Use a lamb's wool pad
- Do not let the buffer exceed 1200 RPM
- Do not allow the lamp lens to get hot. They should not get "hot to the touch", just warm.
3. Do not use solvents such as paint thinner, gasoline or corrosive solvent as a cleaner when washing head or tail lamps.
- Solvents will cause cracks on head lamp and tail lamp lenses. The cracking may not occur immediately. If the solvent permeates the
surface of the plastic lens, it increases the likelihood that the lens will crack under thermal stress when the lights are turned on.
NOTE: Lamps with a hazed appearance from the micro-cracking caused by the use of solvents are not eligible for warranty replacement.
Keys - Cutting Information.

Group: GENERAL
Number: 99-00-008
Date: OCTOBER, 1999
Subject: KEY CUTTING INFORMATION

Model: ALL
DESCRIPTION:
This bulletin provides key cutting information for all Hyundai vehicles using Curtis Industries key cutting equipment. You may either order the
factory keys from Hyundai, through your facing PDC, or order stamped keys from Curtis Industries.
Additional information for Curtis Industries key cutting equipment can be found at their website: www.curtisindustries.com or by calling
1-800-555-2878.
KEY IDENTIFICATION CHART

KEY CUTTING APPLICATION CHART

PC+ COMPUTERIZED CUTTERTechnical Service Bulletin # 98-80-005 Date: 980401
'A' Pillar - Wind Noise at Highway Speeds

Group: TRIM
Number: 98-80-005
Date: APRIL, 1998
Model: 1995 - 98 SONATA
Subject:
SONATA WIND NOISE AT RH "A" PILLAR
DESCRIPTION:
Some 1995-98 Sonata vehicles may experience a wind noise in the area around the right "A" pillar. The noise may be heard primarily when driving
at high speeds (60+ mph) into a headwind. The noise is a loud resonant hum, similar to a "kazoo", and may be difficult to precisely locate. The
sound may originate from the general area around the right outside mirror. Pressing on or opening the passenger right front window glass may
dampen the sound.
The wind noise may be caused by the right hand drip rail moulding vibrating against the right front "A" pillar. The noise is transmitted through the
"A" pillar and transferred into the interior, making it difficult to identify and locate.
Diagnosis Procedure
When diagnosing a wind noise, it is important to get an accurate customer description. Detailed information will reduce diagnosis time and ensure
the condition is repaired. The following questions will help the process:
1. At what speed does the noise occur?
2. At what time of day?
3. What type of road?
4. Was the vehicle traveling against a head wind? No wind? Cross wind? or Tail wind?
5. What was the approximate air temperature?
6. Is the condition repeatable?
Make every effort to get the above information, because it will help identify the nature of the wind noise.
Try to duplicate the condition. Verify if the noise originates from the "A" pillar area. Press on or open the window glass to verify if the noise stops.
Service Procedure
An additional drip rail moulding clip may be added between the 2nd and 3rd clips, about 2/3 of the way up the "A" pillar, to eliminate the wind
noise.
1. Press up on the inside of the drip rail midway up the "A" pillar. Insert a Hyundai Trim Removal Tool (Special Service Tool part number
09800-21000) between the "A" pillar and the drip rail moulding.
Note:
The Hyundai Trim Removal Tool is strongly recommended for this repair. The use of other tools may result in paint damage.
2. Carefully slide the Trim Removal tool up to the third (3rd) clip. Position the tool just above the clip.
3. Place the tip of the tool on the outside of the sheet metal flange (drip rail). Press the tool down to disengage the clip.
4. Repeat procedure to disengage the two lower clips on the drip rail.
5. Insert a new clip between the 2nd and 3rd clips, about 2/3 of the way up the "A" pillar.
6. Press drip rail moulding back into place. Verify that the drip rail moulding is flush and even with the "A"' pillar. If it is gapped, twist the drip
rail moulding down into the "A" pillar, while pressing it into place to fully seat the clips.
Parts/Warranty Information
PART NAME PART NUMBER
CLIP-DRIP RAIL MLDG FR 87789-34000
WARRANTY INFORMATION Technical Service Bulletin # 99-90-004 Date: 990401
Air Bag Assemblies - Repair Kit Part Numbers

Number: 99-90-004
Date: APRIL, 1999
Model: ALL
Subject
AIR BAG REPAIR KIT PART NUMBERS
DESCRIPTION:
When repairing a Hyundai vehicle that has been involved in an accident where the front air bags have deployed, the following components must be
replaced:
1. Deployed air bags
2. SRS control module assembly (computer)
3. Air bag control module assembly machine screws
4. Clock spring contact assembly
5. Air bag wiring harness

6. Front seat belt assemblies in vehicles with deployed seat belt pretensioners.
When repairing a vehicle where just the seat belt pretensioners have deployed, the following components must be replaced:
1. The deployed seat belt pretensioners
2. Air bag wiring harness
3. 1999 Elantra: Air bag SRS CM assembly

1999 Sonata: The SRS CM should be checked with the scan tool.
^ If the scan tool (under the SRS Data Menu) shows from 1 to 5 "BELT PRE FIRINGS", and no other codes, the SRS CM can be reused. If
it shows 6 or more "BELT PRE FIRINGS", the SRS CM must be replaced.
When repairing a vehicle where one or both side air bag(s) have deployed, the following components must be replaced:
1. The front seat back assembly(s)

2. The Air bag wiring harness
3. Air bag SRS CM assembly
4. Satellite sensor for the side which deployed
NOTE:
After any collision, all seat belts worn by vehicle occupants must always be replaced. This includes both the seat belt and the buckle.
Hyundai has developed air bag repair kits to assist dealers when replacing components after a front air bag deployment. The air bag repair kit
includes items 2-5 listed in the front air bag section of this TSB. Failure to replace all of the parts listed may affect the supplemental restraint
system (SRS) in the event of a subsequent accident. In addition to ordering the air bags and seat belts (which are color specific), an air bag repair kit
should also be ordered. The part numbers for these kits are listed in the illustration.
^ Collision repair is not covered under warranty.

^ Warranty coverage does not apply to complete repair kit.
Air Bag System - Diagnostics

Group: ELECTRICAL
Number: 00-90-008
Model: ALL
Subject:
AIR BAG SYSTEM DIAGNOSTICS
DESCRIPTION:
This TSB provides general instructions for diagnosing the Supplemental Restraint System (SRS), also known as the Air Bag System.
GENERAL INFORMATION
The following acronyms and terms are commonly used for the air bag system:
^ DAB Driver Air Bag (in the steering wheel)
^ PAB Passenger Air Bag (in the dash in front of the passenger seat)
^ DSAB Driver Side Air Bag (in the left front seat)
^ PSAB Passenger Side Air Bag (in the right front seat)
^ SAB Side Air Bag
^ SBP Driver Seat Belt Pretensioner
^ PSBPT Passenger Seat Belt Pretensioner
^ PPD Passenger Presence Detector
^ Squib The firing circuit in the airbag/pretensioner.
^ SRSCM Supplemental Restraint System Control Module
^ Shorting Bar "Shorting Bars" are spring-loaded contacts which purposely short the air
bag or pretensioner contacts together when the SRSCM connector is
removed to prevent inadvertent deployment.
GENERAL SAFETY PRECAUTIONS WHEN SERVICING A VEHICLE EQUIPPED WITH AIR BAGS:
The following are general safety rules for working on a vehicle equipped with an Air Bag System. Be sure to review the specific safety instructions
in the correct shop manual for the vehicle being serviced.
1. Before performing service on any component in the Air Bag System, turn the ignition key off and disconnect the negative battery terminal.
Wait at least 30 seconds for the back-up power in the SRSCM to dissipate before resuming work.
2. Always install new parts when making replacements. (Never install air bag parts from another vehicle.)
3. Never attempt to disassemble the parts from an air bag system.
4. If any air bag system component has been dropped, or if there are any cracks, dents, or other visible defects, replace that component with a
new one.
5. Disconnect the negative battery terminal before performing any welding on the vehicle.
6. Do not make any sharp blows or impacts on the vehicle, especially near the SRSCM or the satellite sensors, until after the battery negative
terminal has been disconnected for at least 30 seconds.
7. After completing the diagnosis and repair, always check for SRS codes generated during the repair of the system. Verify there are no new
codes indicating items requiring service. Clear all codes after repairs have been completed.
Procedure
The basics for diagnosing a Supplemental Restraint System:
1. Clearly identify the customer description of the condition to be serviced, when it happens, under what conditions, over what type of road
surface.
2. Using the Hi-Scan Pro, read the codes from the system. Check carefully to see if the code is an active or history code. History codes may be
more difficult to diagnose, since the condition that set the code may no longer be present. This will make the customer's description very
important in determining why the vehicle was brought in for repair.
^ Active Code - Indicates the condition that set the code is still present.
^ History Code -Indicates that the condition that set the code is intermittent or no longer present. (In some cases, if the condition has not rep
3. Identify that part of the system to which the code and the customer description apply. At this time you may have enough information to
determine the service procedure, but usually some diagnosis will be required.
CAUTION:
Before proceeding with the diagnosis, the negative battery cable must be removed from the terminal for a minimum of 30 seconds.
4. Access the SRSCM connector. Refer to the appropriate shop manual or electrical trouble shooting manual for the exact location. Determine
which pins in the connector are used for the circuit to be diagnosed. If the circuit contains an air bag or seat belt pretensioner, unplug it and
plug in the dummy load.
5. Dummy loads are used to test the wiring in each air bag or pretensioner circuit. The dummy load is used to simulate the electrical "load" or
resistance of the air bag or pretensioner. This allows the circuit resistance to be measured safely, without accidentally deploying the air bag/
pretensioner.
^ Use the appropriate adapter and the dummy load. Unplug the air bag/ pretensioner and plug the dummy load into the air bag wire harness.
Adapters are shown.
^ Connect the adapter to the dummy load 2.0 Ohm connector for air bag circuits.
^ Connect the adapter to the dummy load 2.2 Ohm connector for pretensioner circuits.
6. Attach a good quality DVOM to the red and black leads on the diagnosis checker (SST # 0957A-38000). Use the pins on the diagnosis
checker to probe the pins in the SRSCM wire harness connector. Based on how the circuit operates, you may be looking for resistance or
voltage. If a shorting bar in the connector affects the circuit, use the plastic wire tie end on the SST to open the shorting bar. If measuring
through a dummy load, you should measure the dummy load resistance plus 0.0 to 0.2 Ohms for wire and connector resistance, and 0.2 Ohms
for the clock spring resistance.
A NOTE ON USING THE DIAGNOSIS CHECKER (SST # 0957A-38000):

The checker is designed to work with the sharp probes found on most common multimeters. Just push the probe into the female pins in the white
plastic connector on the SST. Some multimeters have large handles on the probes, like the Fluke brand. In this case, use a pin removal tool to pop
the black wire terminal from the white connector, leaving just the red wire in place. This will allow the multimeter to connect to the SST.
SRS DIAGNOSTIC TROUBLE CODE INDEX
HOW TO DIAGNOSE THE SYSTEM (BASED ON THE DIAGNOSTIC CODE
CIRCUIT RESISTANCE HIGH, LOW, OR OPEN (CODES B1345, B1346, B1347, B1351, B1352, B1353, B1360, B1361, B1362, B1366,
B1367, B1368, B1377, B1378, B1379, B1382, B1383, B1386)
These codes may indicate an open connector, but may also include detection of a deployed air bag or seat belt pretensioner, a connector with
unusually high resistance, or an open/short circuit in the wiring.
Active Codes:
^ Check all of the connections (including the clock spring on the DAB circuit),
^ Connect the dummy load, and access the SRSCM wire harness connector.
^ Check for 2 ohms (2.2 ohms on the SBPT circuits) across the terminals in the SRSCM connector. (If there are less than 0.3 ohms, check to be
sure that you opened the shorting bar. Refer to step 6 of this TSB for instructions).
^ Locate the source of the high resistance.
If the circuit tests OK, reconnect the SRSCM, leave the dummy load on the circuit, and reconnect the power to the system. Clear the existing code,
then remove the Hi Scan Pro, and cycle the key off, then on. If the code does not reset, switch the dummy load with the air bag/SBPT it replaced
(disconnect the battery while making the switch). If the same code returns, the air bag/SBPT is the cause of the code. If the code does not return
with either the dummy load or the air bag/SBPT, there is an intermittent condition.
Historical codes:
^ Check for a partially connected connector; a connector pulled very tight, or a connector that may be pulled while the vehicle is driven.
SEAT BELT SWITCH OPEN/SHORT TO BATTERY/SHORT TO GROUND (CODES B1511, B1512, B1513, B1514)
These codes may indicate an open circuit, or a short to power/ground. Test from the SRSCM connector using the same procedure as the circuit
resistance codes above, but no dummy load is required.
^ Resistance between the two wires in each circuit should range between 1000 ohms and 4000 ohms (seat belt unlatched and latched).
^ Resistance to ground should be infinite. If there is a reading to ground, reconnect the battery and measure the circuit voltage (the SRSCM is still
unplugged). Zero volts means the circuit is shorted to ground.
12V means the circuit is shorted to a power circuit.
For Historical Codes check for an intermittent short or a loose connector.
CIRCUIT SHORT TO BATTERY OR SHORT TO GROUND (CODES B1348, B1349, B1354, B1355, B1363, B1364, B1369, B1370, B1380,
B1381, B1384, B1385, B1401, B1402, B1404, B1405)
These codes may result from to a short to ground or 12 Volts in the circuit. The satellite sensor circuits will indicate code B1405 if they are
unplugged, or if the connector is pulled too tightly.
Active Codes:
^ The protective yellow wire covering may make it easier to see how the short occurred if it results from wiring damage.
^ Trace the system wiring to see the damage.
^ With the power off, the dummy load connected, and the SRSCM unplugged, you may be able to use a "Short Finder" to locate the short if it
cannot be found visually.
Historical Codes:
^ Check for an exposed wire,
^ Check for damage to the wire loom
^ Check for a connector pulled very tight. The damage has to make intermittent contact with ground or a 12 Volt circuit.
PPD SHORT TO BATTERY, SHORT TO GROUND, OPEN CIRCUIT, SHORT CIRCUIT (PPD RESISTANCE READ DIRECTLY BY SRSCM
) (CODES B1461, B1462, B1463, B1464)
These codes may indicate an open circuit, or a short to power/ground. Test from the SRSCM connector (no dummy load is required).
^ Use an Ohm meter to test the resistance of the PPD sensor from the SRSCM connector. The resistance should vary from very high resistance
with no weight on the passenger seat to lower resistance with weight (greater than 50k Ohms with no weight to less than 50k Ohms with 33
lbs). There is a diode inside the PPD sensor, which will affect the values measured, but the overall measurements will be similar. If there is a
reading with the DVOM connected one way but not when connected the other way, the PPD sensor has an open circuit.
^ Resistance to ground should be infinite. If there is a reading to ground, reconnect the battery and measure the circuit voltage (the SRSCM is still
unplugged). Zero volts means the circuit is shorted to ground. 12V means the circuit is shorted to a power circuit.
For Historical Codes look for an intermittent short or a loose connector.
SATELLITE LEFT/RIGHT OPERATION, PPD OPERATION, SATELLITE COMMUNICATION ERROR, PPD COMMUNICATION ERROR
(CODES B1400, B1403, B1406, B1407, B1408, B1409, B1410).
These codes indicate an error with the signal coming from the sensor to the SRSCM. The PPD circuit has power and ground wires as well as the
signal wire. The Satellite sensors have a pair of signal wires per sensor.
NOTE:
Code B1409 indicates a different side (Left/Right) on different models, but the diagnostic steps are the same.
Active Codes:
^ Check each connection in the suspect circuit.
^ Use a DVOM to measure the continuity of each wire from the sensor to the SRSCM connector.
Historical Codes:
^ Check for a partially connected connector
^ Check for a connector pulled very tight. For codes B1406 or B1407:
^ Use a test light to verify the power and ground wires to the PPD interface. With the SRSCM connector unplugged, reconnect the battery and
turn on the ignition key. At the PPD connector, connect the test light between the ground wire and the power wire (pin 4 to pin 1). The test light
should illuminate brightly.
^ Use an Ohm meter to test the resistance of the PPD sensor. With the sensor connector unplugged from the interface, measure the resistance
between the two leads as pressure is applied to the center of the seat cushion. The resistance should vary from very high resistance with no
weight to lower resistance with weight (greater than 50k Ohms with no weight to less than 50k Ohms with 33 lbs). There is a diode inside the
PPD sensor, which will affect the values measured, but the overall measurements will be similar. If you get a reading with the DVOM
connected one way but not when connected the other way, the PPD sensor has an open circuit.
^ If these tests are OK, and the code is an active code, replace the PPD interface. If the code was historical, check for a partially connected
connector or a connector pulled very tight.
BATTERY VOLTAGE TOO HIGH OR LOW (CODES B1111, B1112)
These codes indicate that the battery voltage was too high or too low while the system was operational. This code will not set a historical code, the
light will turn off after the input voltage returns to the 10 to 16.5 volt range. It is important to note that the ground wire is an integral component in
the system. This battery voltage may measure low at the module if the ground wire is not fully connected to ground.
1. Test the voltage across the battery, verify that the battery voltage is about 13 to 15 volts when the engine is idling.
^ If it is not, diagnose the battery and the charging system, as per the shop manual.
2. Access the SRSCM connector (disconnect the battery and wait 30 seconds before removing the connector).
3. Test the voltage between the power supply pin and the ground pin of the SRSCM connector with a voltmeter and a test light (to load the
circuit). It should be within the 10 to 16.5 volt range while the test light is illuminated.
CAUTION:
Do not probe the SRSCM connector directly. Use the diagnosis checker harness (SST # 0957A38000) as shown.
^ If it is not within the 10 to 16.5 volt range, test the voltage between the power supply pin of the SRSCM connector to a good ground. If
that voltage is correct, but the voltage between the power supply pin and the ground pin of the SRSCM connector was not, then diagnose
the ground wire.
If the voltages at the connector check out OK, then reconnect the SRSCM (disconnect the battery and wait 30 seconds before connecting the
connector), and start the car. If the same code is repeated, then replace the SRSCM.
CONTROL MODULE INTERNAL FAULT, SATELLITE SENSOR WRONG ID, ECU MISMATCHING (CODES B1414, B1415, B1620,
B1661)
The SRSCM must be replaced.
CRASH RECORDED, CRASH RECORDED LH/RH SIDE AIR BAG (CODES B1650, B1651, B1652, B1660, B1663)
These codes indicate that the SRSCM deployed the air bags indicated. These codes cannot be reset, as the module can only deploy an airbag one
time. The module will need to be replaced. The seat belts worn during the collision, the wire harness, and the deployed air bags must also be
replaced. (refer to TSB# 00-90-004)
SEAT BELT PRETENSIONER DEPLOYMENT (CODES B1662, B1664)
These codes indicate that a seat belt pretensioner was deployed. These codes will be accompanied by codes B1361 or B1367. Replace the
appropriate seat belt and buckle, then clear the codes. This repair is not covered by the vehicle warranty.
BELT PRETENSIONER DEPLOYED 6 TIMES (CODE B1658)
The seat belt pretensioners have deployed 6 times, the maximum allowable for one SRSCM. Replace the SRSCM at the same time as the seat belt
pretensioner(s). This repair is not covered by the vehicle warranty
WARNING LAMP OPEN, SHORT TO GROUND, SHORT TO BATTERY (CODES B2500, B2503, B2504)
The SRSCM has detected a warning lamp circuit condition requiring diagnosis. It detects the voltage from the warning lamp circuit. There should
be 12V when the warning lamp is off, and OV when the warning lamp is on. This code can also be set if the vehicle battery is discharged
sufficiently so that the engine cannot start, and then it is subsequently jump started. This requires asking the customer about the events leading to
the warning lamp illumination.
1. Check that the fuse or the warning lamp circuit has power. It uses a different fuse than the SRSCM. Refer to the shop manual or electrical
trouble shooting manual for the correct fuse. Verify that it has power.
2. Evaluate the warning lamp circuit at the SRSCM connector.
^ Access the SRSCM connector (disconnect the battery and wait 30 seconds. Remove the connector from the SRSCM.
^ Reconnect the power.
^ Use the diagnosis checker SST to test for power on the warning lamp input.
^ Use the wire tie end on the SST to open the shorting bar between pin 7 (warning lamp input) and pin 6 (ground). Then measure the
voltage (with a DVOM and the Diagnosis Checker) across pins 6 & 7. There should be 12 volts. If not, verify that pin 6 has good
continuity to ground, verify the warning lamp is good, and look for an open connector or open circuit in the wire between the fuse and the
lamp, and between the lamp and the SRSCM.
^ Verify that you can turn the warning lamp on and off by removing the wire tie from the shorting bar (on when shorted), and re-inserting it
into the shorting bar (off when shorting bar is opened). If the warning lamp stays on, then look for a short to ground between the SRSCM
and the warning lamp. You may need to remove the bulb from the instrument cluster depending on the type of short finding equipment
used. A visual inspection of the harness will probably reveal the short location.
3. If the tests show the proper inputs, then reconnect the SRSCM (disconnect the battery and wait 30 seconds before reconnecting the
connector), clear the code, disconnect the HDS Scanner/Hi Scan, cycle the key off for 30 seconds, turn the key on, and check to see if the
code is reset. If it is, then replace the SRSCM.
ELECTRICAL TROUBLESHOOTING MANUAL SCHEMATICS

The five illustrations contain schematics for the Air Bag System in each of the 2000 models: Accent, Elantra, Santa Fe, Sonata and Tiburon. These
schematics are copies of those found in the shop manuals or ETMs and the page numbers are shown on each illustration.
Security System - Updates

Number: 97-90-015
Date: NOVEMBER 1997
Model: ALL
Subject:
SECURITY SYSTEM UPDATES (CLIFFORD)
DESCRIPTION:
This bulletin contains updated information for Hyundai's security system. Change In The Valet Switch Location:
Beginning in September, 1997, the security valet switches are installed in the following locations:
Tiburons & Elantras:

The valet switch is mounted inside the driver's side kick panel plastic trim, behind the fuse box door.
Accents:
The valet switch is located near the instrument panel dimmer switch.
Sonatas:
The valet switch is still located on the surface of the driver's side kick panel plastic trim but closer to the corner, near the latch side of the fuse box
door.
Light-Emitting Diode (LED) Location:

The LED light on Elantras, Tiburons and Sonatas is located on top of the steering column shroud. The LED light on Accents is located on the left
side of the instrument panel near the instrument cluster.
The LEDs are installed from the top (previous to this change, the LEDs were mounted from the bottom).
Elantra, Sonata & Tiburon:

The LED light is located on top of the steering column shroud.
Accent:
The LED light is located on the left side of the instrument panel near the instrument cluster.
Security System Remotes:

Both remotes are located in the glovebox when the vehicle is delivered from the Port.
Security System Mode:

Vehicles are shipped from the Ports with the security system in normal mode (not in valet mode).
Keyless Entry Feature: (Clarification)
^ The basic security system DOES NOT include the Keyless Entry feature. In order to obtain this feature, it must be purchased separately.
Note:
The only exception to this is Sonata models that are equipped with the factory power door locks; in which case, the Keyless Entry feature is
included with the basic security system.
^ The Keyless Entry feature operates the driver's door lock ONLY, unless the vehicle is equipped with factory power door locks; in which case,
the feature will operate all door locks simultaneously.
Security System Door Window Sticker Modification:
Beginning in September, 1997, the Hyundai security system door window sticker has been changed. The new sticker:
^ is clear instead of silver

^ is 25% smaller than the previous sticker
^ contains different graphics
The modification improves the appearance of the sticker.
Security System Remote Battery:

If the battery in the security system remote control has been discharged the LED should not light up when either of the two buttons are pushed.
Replace the battery by removing one screw and separating the remote housing.
Replacement battery part no. 00243-16150.

Security Systems - Availability/Applications

Number: 01-90-003
Date: APRIL, 2001
Model: ALL
Subject:
HYUNDAI SECURITY SYSTEM PART NUMBERS
DESCRIPTION:
This bulletin provides the following information:

1. Currently available security Systems that are applicable to Hyundai vehicles
2. System application by model and model year
3. Differences in the control module appearance

4. Quick reference chart for ordering replacement parts

The Control Module for the 2001 Elantra, Santa Fe and XG300 Factory security Systems is incorporated in the Electronic Time and Alarm Control
System (ETACS). See photos shown.
Hyundai Security Systems Part Number NotesTechnical Service Bulletin # 01-90-011 Date: 010901
Security System - Programming

Number: 01-90-011
Model: ALL
Subject:
PROGRAMMING HYUNDAI SECURITY SYSTEM
DESCRIPTION:
This bulletin provides programming procedures for all security Systems available on Hyundai vehicles. There are three different types of security
systems available: Clifford Supplied System1 Directed Electronics, Inc. (DEI) Supplied System and Factory Installed System. The chart shows
which system is available for each model year Hyundai.
NOTES:
^ The three security system kits/parts are not interchangeable.
^ Refer to TSB 01-90-003 for Hyundai Security System Part Numbers.
^ Refer to pages 12-14 for security system transmitter, Valet Switch and LED illustrations.
Programming the Clifford System

NOTE:
The Clifford Security System is not interchangeable with the DEI or Factory Installed Systems.
The table shown provides information to program the Clifford System's various features. Although some of the headings are self explanatory, a
brief description of each will assist in the use of the table:
^ Features: Features and/or options of security system.
^ Procedure to Accomplish the Feature Setting:
1. Select the feature you wish from the table shown. Note the number of cycles (or flicks).
2. Turn the vehicle's ignition switch to the "ON" position.
3. Immediately flick the valet switch up and down the number of times noted for the feature you wish to program (to help you count, you will
hear a single chirp confirmation each time you flick except for the 2000 Sonata Keyless Clifford System).
a. If noted, perform the "Secondary Action".
b. If noted, wait for the "Program Completion Confirmation".
4. Turn the ignition off. Repeat steps 1 - 4 for any other feature you wish to program.
^ Original Setting: How the system is delivered from the manufacturer.
^ # Of Cycles: The number of "Valet Switch Cycles" (on/off) required to accomplish programming change. Each complete cycle will be followed
by a siren "chirp" or a horn "beep".
^ Secondary Action: When required, this is done after last "Valet Switch Cycle".
^ Completion Confirmation: What will occur if programming is successful.
CLIFFORD SYSTEM:
1. Remote transmitter (P/N 00243-16110).
2. Valet Switch (P/N 00243-16130).

3. LED.
Programming the DeI System

The following information provides a procedure to add new remotes and program the DEI Security System1s various features. It is possible to
access and change any of the feature settings using the Valet Switch.
To Add a New Remote:
The keyless entry receiver CPU will learn up to four different remotes. If there are more than four remotes introduced to the system, the transmitters
added first will be deleted. (First remote in, first remote out).
NOTE:
The LED (P/N 00265-11001) and the Valet Switch (P/N 00265-11000) are not included in the DEI keyless kit. The two parts are required in
order to program and/or add new remotes. The LED and Valet Switch are included with the security upgrade kit and as part of the replacement
transmitters.
Make sure to keep an LED and Valet Switch available for use to assist customers to program the keyless kits.
1. Plug the Valet Switch into blue 2-pin port on side of keyless entry receiver (CPU).
2. Plug LED into white 2-pin port on side of keyless entry receiver (CPU).
3. Turn ignition switch to the "on" position.
4. Press and RELEASE Valet Switch seven times.
5. Press and HOLD Valet Switch.
6. LED should respond by flashing seven times.
7. Press button I (lock button) of remote you wish to add.
8. Release Valet button.
9. Turn ignition switch "off".
10. Test each remote for complete function.
Program Features:
NOTE:
This procedure is applicable for security upgrade only.
1. Open the vehicle door.
2. Turn the ignition on, and then off.

3. Select a feature (refer to table shown).
Locate the Valet Switch underneath the driver side dashboard area. Press and release the Valet Switch the number of times (cycles)
corresponding to the feature corresponding to the feature you wish to program. For example, to access the Siren Duration feature, press and
release the Valet Switch three times. Then press the button once more and HOLD it. The siren will chirp the number of times corresponding
to the feature you have accessed.
NOTE:
The default settings are indicated with asterisks. A description of the system features are outlined.
4. Program the feature.
While holding the Valet Switch, you can toggle the feature on and off using your factory remote transmitter. Pressing the button that locks
the doors (button I) will select the one-chirp or default setting. Pressing the button that unlocks the doors (button II) will select the two-chirp
setting.
5. Release the Valet Switch.
6. Test the system to make sure the feature that you have programmed or selected functions correctly.
NOTE:
Once a feature is programmed, other features can be programmed
To access another feature:
^ Press and release the Valet Switch the number of times necessary to advance from the feature you just programmed to the next one you wish to
program. Then press the Valet Switch once more and hold it.
^ For example, if you just programmed the second feature and you would like to program the seventh feature in the menu, you would:
a. Press and release the Valet Switch five times.
b. Press it once more and hold it.
c. The siren would chirp seven times to confirm access to Feature 7.
The Programming procedure will be exited if any of the following occurs:
^ Close the open door
^ Turn the ignition on.
^ No activity for longer than 15 seconds.
^ Press the valet button too many times.
SYSTEM FEATURE DESCRIPTIONS:
*1 ACTIVE/PASSIVE ARMING: When active arming is selected, the system will only arm when the transmitter is used. When set to passive
arming, the system will arm automatically 30 seconds after the last door is closed. To alert the consumer of passive arming, the siren will
chirp and the parking lights will flash 30 seconds after the door is closed.
*2 AUDIBLE ARM/DISARM CONFIRMATION ON/OFF: This feature controls the chirps that confirm the arming and disarming of the
system. In the ON setting (default), the siren will provide audible confirmation when arming and disarming the system. If programmed to the
OFF position, no siren chirps will be heard when arming or disarming.
*3 SIREN DURATION 30/60 SECONDS: In the default setting, the full triggered sequence will continue for 30 seconds when triggered. This
can be programmed to 60 seconds in the system features learn routine.
*4 DOOR TRIGGER INSTANT/DELAYED: In the instant (default) setting, if a door is opened while the security system is armed, the system
will trigger immediately. In the delayed setting, there is a 15-second delay before the doors will trigger the system. This gives the user 15
seconds to disarm the system after a door is opened without having disarmed with the factory transmitter.
*5 DOOR TRIGGER ERROR CHIRP ON/OFF: With the door trigger error chirp programmed off, the system will not report an invalid zone on
arming when the door trigger wire is active. This eliminates the extra chirps that occur when interfacing with vehicles that have exceptionally
long dome light delay circuits.
*6 NO FUNCTION
*7 NO FUNCTION
*8 NO FUNCTION
*9 VALET PULSE COUNT 1 - 5 PULSES: The system can be programmed to count the number presses of the Valet Switch before disarming
the security system. The factory default setting is 1 pulse. The unit can be programmed for 2 - 5 pulses using the unlock button (button II) to
select the setting. (See the Valet Mode section below).
* VALET MODE:
In Valet Mode, the system will not arm, even with the transmitter, but all convenience functions (door locks, etc.) will work normally. This is very
useful when washing or servicing the vehicle.
To enter or exit Valet Mode with the Valet Switch:
1. Turn ignition to the "on" position. Then turn to the "oft" position.
2. Press and release the Valet Switch within 10 seconds. The status LED will light steady if you entered Valet Mode.
To exit Valet Mode, repeat the steps above. The LED will turn off when exiting Valet Mode.
DEI SYSTEM:
1. Remote transmitter (P/N 00265-11002) for 2001 Sonata and 2001 Tiburon.
2. Valet Switch (P/N 00265-11000).
3. LED (P/N 00265-11001).

Factory Installed System
The 2001 MY Elantra, Santa Fe and XG300 contain factory alarm and keyless entry. These Systems are installed by HMC during production of
these vehicles. The factory system cannot be added to a vehicle; the vehicle must be ordered with it. The factory security kit is NOT
interchangeable with the Clifford or DEI security systems.
NOTE:
The factory security system module is incorporated into the vehicle's Electronic Time and Alarm Control System (ETACS). (See photos
shown). The factory system does not contain an LED status indicator, impact shock sensor, valet switch, remote panic feature or audible arm
and disarm confirmation.
Code Saving Tool Kit:
A programming Special Service Tool can be used to add new or replacement remotes to the 2001 MY Elantra, Santa Fe and XG300 security
Systems. The tool (P/N J-45346) can be purchased through SPX/Kent-Moore at 1-800-345-2233. Each dealership was supplied one tool in January,
2001. A maximum of two remotes may be used for each system.
^ The J-45346 tool (Transmitter Programmer Kit) is required to reprogram the ETACS control module to recognize remotes. To reprogram
the ETACS control module, the following three items are required.
^ Code Saver (P/N J-45346-TXR1)
^ Code Saver Main Harness (P/N J-45346-TXR0)
^ Jumper Cable (P/N J-45346-TXR2)
Programming Instructions for Factory Installed System:

1. Verify that the power bar in the interior fuse box is in the "On" position.
2. Remove the ignition key.
3. Connect the Code Saver Main Harness (J-45346-TXR0) and the Code Saver (J-45346-TXR1) together securely.
NOTE:
For the 2001 XG300, connect the Code Saver Main Harness and the Jumper (J-45346-TXR2) together securely.
4. Connect Code Saver Main Harness to the white 10-pin multipurpose connector located under the dash.
5. Move Code Saver switch from "Ready" to "Save".
NOTE:
Disregard this step when programming the 2001 XG300.
6. Press the "Lock" or "Unlock" button on either remote and release after the LED pulses on and off ONE cycle.
7. Repeat previous step with remaining remote. Move Code Saver switch back to "Ready" position.
NOTE:
Disregard this step when programming the 2001 XG300.
8. Unplug Code Saver Main Harness from vehicle's multipurpose connector.
9. Test remotes.
NOTE:
The ETACS control module in a vehicle can only be programmed to accept two remote transmitters and MUST be programmed for both remote
transmitters at the same time.
FACTORY SYSTEM:
1. Remote transmitter (P/N 95411-3A200) for 2001 Elantra and 2001 Santa Fe.
2. Remote transmitter (P/N 95430-39200) for 2001 XG300.

Security/Alarm System - Diagnostic Guide

Group:
BODY ELECTRICAL
Number:
02-90-009
Date:
JUNE, 2002
Model:
1994-2001 SONATA, 1995-1999 ACCENT, 1996-2000 ELANTRA, 1997-2001 TIBURON
Subject:
DIAGNOSTIC GUIDE FOR CLIFFORD AND DEI SECURITY SYSTEMS
DESCRIPTION:
This bulletin contains information to be used for the diagnosis and repair of Hyundai's Clifford and DEI security Systems.
TABLE OF CONTENTS
DIAGNOSTIC PROCEDURES (CONDITION/SOLUTION)
CLIFFORD SECURITY SYSTEMS (PROGRAMMING GUIDE OF SELECTABLE FEATURES)
DEI SECURITY SYSTEMS (PROGRAMMING GUIDE OF SELECTABLE FEATURES)

CLIFFORD SECURITY SYSTEMS WIRE HARNESS DIAGRAM

DEI KEYLESS ENTRY SYSTEM DIAGRAM (WHITE 12-PIN CONNECTOR)

DEI SECURITY SYSTEM DIAGRAM (BLACK 12-PIN CONNECTOR)

HYUNDAI SECURITY SYSTEM PART NUMBERS
Note 1:
All tests and measurements must be made with a digital voltmeter. Damage may result to the control unit or vehicle if a test-light is used.
Note 2:
All voltages should be measured from the security system's BLACK ground wire or fused +12 volt input wire unless otherwise specified.
Note 3:
Refer to the provided system diagrams where necessary.
Refer to the following previous TSB publications where appropriate:
1. 96-90-007 Troubleshooting guide for new security system (Clifford)
2. 00-90-002 2000 Elantra and 2000 Tiburon security system no crank condition
3. 01-90-003 Hyundai security system part numbers
4. 01-90-007 2001 Sonata and Tiburon security upgrade "Door Lock Learn Procedure"
5. 01-90-011 Programming Hyundai security systems

DIAGNOSTIC PROCEDURES
CLIFFORD SECURITY SYSTEMS
Programming Guide of Selectable Features

To enter programming mode, turn the ignition on and immediately begin flicking the valet switch the appropriate number of times. You must begin
the programming steps within 30 seconds of turning the ignition on or the control module will ignore the valet switch until you turn the ignition off
and then back on again.
NOTE:
The # of flicks required is an up/down or a down/up motion (counts as 1 cycle) depending on how the switch was originally installed. You
MUST start in the valet OFF position (LED off).
EXAMPLE:
To add a new remote control to channel 1 (arm/disarm), turn the ignition on and then immediately begin flicking the switch up/down, up/down,
up/down, etc. 13 times. Within 10 seconds, press button 1 on the new remote control. The system will "chirp" once (if equipped with a siren/horn)
to acknowledge that it has stored the new remote control code into memory.
DEI SECURITY SYSTEMS
Programming Guide of Selectable Features
To enter programming mode, open a vehicle door and then turn the ignition on and then off.
1. Press and release the valet switch the number of times corresponding to the feature you wish to program. For example, to access feature 3
(siren duration), press and release the valet switch three times.
2. Then press the button once more and HOLD it. The siren will chirp the number of times corresponding to the feature you have accessed.
3. Then, while holding the valet switch button, program which setting by pressing the remote control buttons. Pressing the arm button will
select the one-chirp setting while pressing the disarm button will select the two-chirp setting.
4. You may now release the valet switch.
NOTE:
The default settings are indicated in bold.
Vehicle Identification Number - Decoder

Group
GENERAL
Number
00-00-003
Date
SEPTEMBER, 2000
Model
ALL
Subject
VIN DECODER
DESCRIPTION:
This bulletin provides information concerning the vehicle identification number (VIN) for all Hyundai models that have been sold in the United
States. Refer to this TSB for definitions for each of the seventeen (17) characters in the VIN sequence.
Vehicle Identifiication Number - Decoder

Group: GENERAL
Number: 97-00-004
Model: ALL
Subject:
VIN DECODER
This bulletin provides information concerning the vehicle identification number of all Hyundai vehicles.
VEHICLE IDENTIFICATION NUMBER

Emissions - OBD II Readiness Test Drive Cycles

Group
Number
02-36-030
Date
December, 2002
Model
SONATA 1996-1998
Subject
OBD-II READINESS TEST DRIVE CYCLE FOR 1996-1998 SONATA
DESCRIPTION:
This TSB describes Drive Cycles which may assist the vehicles OBD-II system to complete the necessary emissions systems tests and set the
OBD-II Readiness Monitors to display READY (or COMPLETED -- described simply as READY in this TSB). This TSB specifically covers the
1996-1998 Sonata.
The drive cycles described below are specifically designed to set the following items:
^ CATALYST
^ EVAP. PURGE
^ 02 SENSOR
^ 02 SENSOR HEATER
^ EGR
READINESS MONITOR:
The readiness monitors indicate if all the necessary emissions systems tests have been completed by the ECM.
This feature is a part of the OBD-II system.
It ensures that vehicles have had sufficient time to conduct all necessary emissions related diagnostics:
^ after a repair which resulted in the power to the ECM being interrupted
^ or resulted in clearing of Diagnostic Trouble Codes (DTCs) using a scan tool.
Information
Depending on the model year of the vehicle, follow the correct Drive Cycle pattern.
IMPORTANT
In order to set the Readiness Monitors to READY, the vehicle must successfully complete the appropriate Drive Cycle TWO TIMES.
DEFINITION OF TWO CONSECUTIVE DRIVE CYCLES:
That is, the vehicle must:
1. Complete the Drive Cycle.
2. The ignition key must be turned to the OFF position and stay off for at least 30 seconds.
3. Complete the Drive Cycle a second time.
IMPORTANT
The two Drive Cycles MUST be completed on two CONSECUTIVE drives.
CONSECUTIVE means that the two successful OBD-II Readiness Drive Cycles cannot be interrupted by any other kind of driving between
them.
WARNING:
PRE-EXISTING CONDITIONS ON THE VEHICLE:
The vehicle will not set the Readiness Monitors even if the Drive Cycles are performed correctly, if the vehicle has certain pre-existing
conditions.
Such as:
^ Stuck Open Thermostat: If the thermostat is stuck open, the Engine Coolant Temperature (ECT) reading may drop below 176 degrees F.
If the ECT reading drops below 176 F (especially during the steady state highway driving where the airflow across the radiator will cool
the coolant quickly), the Drive Cycle will NOT be effective. In order for the Drive Cycle to "count", the ECT reading must be above 176
F.
^ Radiator Fans Stuck ON: If the radiator fans are stuck ON, the ECT reading may drop below 176 F during the Drive Cycle. As with the
stuck open thermostat, this condition will negate the Drive Cycle.
ROAD CONDITIONS:
The type of road that the Drive Cycle is performed on is important.
The BEST type of road for performing the Drive Cycle is one that is as Level (Flat) as possible.
If the Drive Cycle is performed in an area with hilly terrain it will be more difficult to successfully perform the Drive Cycle. In this case, it may
require that the Drive Cycle be performed more than two times to ensure success.
1996 & 1997 Drive Cycle

IMPORTANT
In the case of the 1996 & 1997 Sonata, in order to set the CATALYST, EVAP. PURGE, 02 SENSOR, 02 SENSOR HEATER and EGR
monitors to READY, ALL FIVE of these diagnostic tests must be completed on the same drive. If only four of the five monitors diagnostics are
completed on a test drive, NONE of the Readiness Monitors will indicate READY. Thus, the drive cycle must be repeated.
The drive cycle described below covers the conditions required to run ALL five diagnostic tests.
DISCUSSION OF DRIVE CYCLES AND MODES:
The chart shows the required driving necessary to complete a Drive Cycle.
IMPORTANT
The Drive Cycle consists of five parts; one MODE 1 and four MODE 2 parts. The engine must not be turned off at any time during the Drive
Cycle. Do NOT turn the engine off between completing different Modes. Only after ALL parts of the Drive Cycle is completed, should the
ignition key be turned off.
MODE 1:
The following information describes, step-by-step, the procedure for completing MODE 1 driving.
STEP 1: (STARTING PROCEDURE)
^ Check to make sure that there are no DTCs stored in the ECM (using the Hi-Scan Pro) and that the Check Engine Light is OFF. If there is a
DTC, repair the vehicle first.
^ Check the Readiness Status. The items indicating NOT READY should be CATALYST, EVAP. PURGE, 02 SENSOR, 02 SENSOR HEATER
and EGR.
^ If the MISFIRE, FUEL SYSTEM or COMPONENT monitors are not ready, then repair any conditions related to these items first.
^ Start the engine.
^ Warm up the engine (coolant temperature at least 176 degrees F).

^ Turn OFF the A/C.
STEP 2: (TRANSIENT TO STEADY STATE DRIVING)
^ Connect the Hi-Scan Pro and go to the Current Data Menu. The three items to look at during the drive cycle are the Engine RPM, Vehicle
Speed and Engine Coolant Temperature (ECT). Using the fix feature of the Hi-Scan, fix these three values in the Current Data Menu.
^ IMPORTANT:
Two people should conduct the drive cycle, one person to drive and the other person to monitor the Hi-Scan Pro readings and keep track of
the driving time.
^ Drive the vehicle to a light traffic road where the required Steady State Driving condition can be duplicated.
^ Any kind of driving is OK before the steady state driving is conducted.
STEP 3: (STEADY STATE DRIVING - THIS IS THE MAIN PART OF MODE 1. THE STEADY STATE DRIVING SHOULD BE DONE ON
A LEVEL ROAD (AVOID HILLS WHENEVER POSSIBLE).
^ Drive the vehicle at a steady state where the engine speed is between 1,700 and 2,500 RPM in high gear (5th speed in a manual transmission
equipped vehicle and D position in an automatic). The vehicle speed should be between 50 and 65 MPH.
^ Drive in the Steady State Mode CONTINUOUSLY for a minimum of 10 minutes.
IMPORTANT:
While driving in the Steady State Mode, carefully monitor the ECT reading. It should always stay above 176 F. If it drops below 176 F,
diagnose the thermostat & ECT & repair. Then restart the Drive Cycle.
VEHICLE SPEED BELOW 50 MPh: The vehicle must be driven within the vehicle speed range CONTINUOUSLY. DO NOT ALLOW THE
VEHICLE SPEED TO DROP BELOW 50 MPH, IF SAFELY POSSIBLE. If the vehicle speed falls below 50 MPH, the time counter for the
steady state driving must be restarted.
EXAMPLE: After 5 minutes and 30 seconds of CONTINUOUS driving between 50 and 65 MPH, the vehicle speed falls below 50 MPH due to
slow traffic. Because the vehicle speed fell below 50 MPH, the steady state driving must be started over. Thus, the 5 minutes and 30 seconds of
driving previously accomplished DOES NOT COUNT TOWARDS THE 10 MINUET REQUIREMENT. A full 10 minutes of CONTINUOUS
driving within the specified vehicle speeds must be achieved to successfully complete the steady state driving part of Mode 1.
VEHICLE SPEED ABOVE 65 MPH: If the vehicle speed goes ABOVE 65 MPH during the Steady State Driving part of Mode 1 the
continuous time counting must be stopped, but the Steady State Driving does NOT have to be restarted. When the vehicle speed falls below 65
MPH, simply restart the time counter from where it was stopped when the vehicle exceeded 65 MPH.
EXAMPLE: After 5 minutes of CONTINUOUS driving between 50 and 65 MPH, the vehicle speed goes above 65 MPH due to the flow of
traffic. Because the vehicle speed is above 65 MPH, the time counter stops at 5 minutes. After a short time, its possible to bring the vehicle
speed below 65 MPH and above 50 MPH. Now, the time counter can be restarted at 5 minutes and continue. Thus, it is not necessary to start the
time counting over from zero in this case.
STEP 4: (EGR MONITORING)
^ After accumulating at least 10 minutes of Steady State Driving, find a safe place to COAST down to a low speed (below 20 MPH) from the
steady state driving speed (50 - 65 MPH). Leave the transmission in D -- ATM or 5th gear -- MTM.
^ When at the location where the vehicle can be coasted down to a speed below 20 MPH, release the throttle and allow the vehicle to COAST
down. DO NOT APPLY the BRAKE, if safely possible, until the vehicle speed has reached 20 MPH or less. Once the vehicle reaches 20 MPH
or less, the brakes may then be applied.
COASTING: Coasting is defined as slowing down without depressing the throttle or the brake.
^ If an attempt to coast to 20 MPH or less was not successful due to traffic (that is, the brake had to be applied prematurely), then bring the
vehicle speed back up to above 50 MPH and try again when safely possible to do so.
^ After successfully coasting to below 20 MPH, bring the vehicle to a stop at a location where the vehicle may idle.
STEP 5: (IDLE-STATE - THIS IS THE LAST PHASE OF MODE 1)
^ After coming to a stop, allow the vehicle to idle for at least 50 seconds (the transmission should be placed in Neutral and the A/C should still be
OFF).
STEP 6: (ENGINE STOP)

^ After 50 seconds of idling, the Idle-State phase of MODE 1 is complete.
^ DO NOT TURN OFF THE ENGINE.
^ Continue the Drive Cycle by driving MODE 2.
MODE 2:
The following information describes, step-by-step, the procedure for completing MODE 2 driving.
STEP 1: (START OF MODE 2)
^ After completing MODE 1, find a light traffic road where the vehicle may be driven at different street speeds of approximately 50 to 15 MPH
for about two minutes.
STEP 2: (TRANSIENT TO STREET DRIVING)
^ From a stop, accelerate slowly up to a speed of 45 to 65 MPH.
^ The transmission should be in D for ATM equipped vehicles and 5th gear for manual transmission equipped vehicles.
STEP 3: (STREET DRIVING -- PART 1)
^ Drive the vehicle at a steady speed of 45 to 65 MPH for at least 30 seconds.
^ The engine speed should be between 1,700 and 2,500 RPMs during this phase.
^ After 30 seconds, slow the vehicle down to the next STEP.
^ Slow the vehicle down to a steady speed of 35 to 45 MPH. The brakes may be applied in the process of slowing down.
^ Drive at this speed for at least 40 seconds.
^ After 40 seconds, slow the vehicle down to the next STEP.

^ Slow the vehicle down to a steady speed of 15 to 25 MPH. The brakes may be applied in the process of slowing down.
^ Drive at this speed for at least 10 seconds.
^ After 10 seconds, find a safe location where the vehicle can come to a stop and idle.
STEP 6: (IDLE PHASE)
^ Put the transmission into Neutral and make sure that the A/C is off.
^ Allow the vehicle to idle at least 5 seconds but not more than 35 seconds.
STEP 7: (END OF MODE 2)
^ If this was the first, second or third time of driving MODE 2 successfully, then repeat MODE 2 (go back to STEP 1 of MODE 2). If not, go to
the next step.
^ If this was the end of the fourth time of driving MODE 2 successfully, then the Drive Cycle is complete.
^ Turn the key to the OFF position. Wait 30 seconds before restarting the engine (or turning the key to the ON position).
^ IF ONLY ONE DRIVE CYCLE HAS BEEN COMPLETED, CONDUCT ONE MORE DRIVE CYCLE. (Two consecutive, successfully
completed Drive Cycles are required to set the Readiness Codes.)
^ After the conclusion of the second drive cycle, turn the engine off (Key in the OFF position) and wait 30 seconds before turning the key to the
ON position. Using the Hi-Scan Pro, check to see if the Readiness Monitors for CATALYST, EVAP. PURGE, 02 SENSOR, 02 SENSOR
HEATER and EGR indicate READY.
^ If not, then check to see if there are any DTC codes or if the Check Engine Light is ON. If yes, then repair the vehicle. After repair is
completed, conduct the Drive Cycle two times.
^ If after the conclusion of the second Drive Cycle, the Readiness Monitors for CATALYST, EVAP. PURGE, 02 SENSOR, 02 SENSOR
HEATER and EGR still indicate NOT READY, then conduct the Drive Cycle one more time and check the Readiness Codes again (the
previous attempts at the Drive Cycle may not have been successfully completed).
1998 Sonata - Step By Step

IMPORTANT
In the case of the 1998 Sonata, in order to set the monitors to READY, only the diagnosis for each of the monitors need to be run on any drive
(It is still necessary to run the diagnosis on at least two consecutive, successful Drive Cycles.). That is, the monitors are NOT linked together.
They can be run independently and will display as READY or NOT READY independently (unlike the 1996 & 1997 Model Year Sonata).
EVAP. PURGE AND EGR (MODE 1):
^ In order to set the Evap. Purge and EGR monitors to READY, drive MODE 1 (as described previously in this TSB).
NOTE
It is NOT necessary to drive MODE 2 in order to run the Evap. Purge and EGR monitors.
^ After the first successful duplication of MODE 1, turn the ignition key to the OFF position and wait 30 seconds before driving MODE 1 a
second time (second Drive Cycle).
^ After successfully completing two Drive Cycles, the Readiness Monitor should indicate READY.
^ After the conclusion of the second Drive Cycle, turn the engine off (Key in the OFF position) and wait 30 seconds before turning the key to the
ON position.
Using the Hi-Scan Pro, check to see if the Readiness Monitors for EVAP. PURGE and EGR indicate READY.
^ If after the conclusion of the second Drive Cycle, the Readiness Monitors for EVAP. PURGE and EGR still indicate NOT READY, then
conduct the Drive Cycle again and check the Readiness Codes again (the previous attempts at the Drive Cycle may not have been successfully
completed).
CATALYST, 02 SENSOR AND 02 SENSOR HEATER (MODE 2):
^ In order to set the Catalyst, 02 Sensor and 02 Sensor Heater monitors to READY, drive MODE 2 (as described previously in this TSB) at least
four (4) times.
NOTE
It is NOT necessary to drive MODE 1 in order to run the Catalyst, 02 Sensor and 02 Sensor Heater monitors.
^ After the first successful duplication of MODE 2 at least four times turn the ignition key to the OFF position and wait 30 seconds before driving
MODE 2 at least four times again (second Drive Cycle).
^ After successfully completing two Drive Cycles, the Readiness Monitor should indicate READY.
^ After the conclusion of the second Drive Cycle, turn the engine off (Key in the OFF position) and wait 30 seconds before turning the key to the
ON position. Using the Hi-Scan Pro, check to see if the Readiness Monitors for Catalyst, 02 Sensor and 02 Sensor Heater indicate READY.
^ If after the conclusion of the second Drive Cycle, the Readiness Monitors for Catalyst, 02 Sensor and 02 Sensor Heater still indicate NOT
READY, then conduct the Drive Cycle again and check the Readiness Codes again (the previous attempts at the Drive Cycle may not have been
successfully completed).
Enhanced Evaporative Emission Control - Diagnosis

Group
FUEL SYSTEM
Number
00-30-003
Date
SEPTEMBER, 2000
Model
ALL MODELS
Subject
ENHANCED EVAPORATIVE EMISSION
CONTROL DIAGNOSIS AND REPAIR FOR
P0442, P0455 AND P1443 LEAK CODES USING
A LOW PRESSURE GAUGE
DESCRIPTION:
This bulletin provides information describing how to use a Low Pressure Gauge for diagnosis of leak codes on enhanced evaporative emission
systems. Diagnostic Trouble Codes (DTCs) P0442, P0455, and P1443 can be diagnosed using a low pressure gauge. In some instances DTGs
P0446, P0440 and P0441 can also be diagnosed using a low pressure gauge.
THE BASICS:
By pressurizing a sealed evaporative emission system, the pressure leakdown rate can easily be measured using a low pressure gauge. The system
should be slowly pressurized to a very low pressure (in this case 20" H20). A properly operating system (one that does not leak) will not lose any
pressure; in fact, with high fuel temperature and high ambient temperature, pressure may increase due to fuel vaporization. If the gauge drops more
than 2 inches of water (0.072 psi) in 1 minute, a leak is present. (If the gauge pressure drops, a leak is present, and the technician must find the
location of the leak and repair it.]
Note 1:
1" H20 = 0.036 psi; 30" H20 = 1.08 psi
Note 2:
The low pressure gauge is a very sensitive tool. DO NOT exceed 30" H20 (1 psi) when pressurizing the system (pressurize SLOWLY!) or the
gauge will be damaged.
Low Pressure Gauge Tool - SPX EVAP Tester P/N J-44680
CONNECTING THE LOW PRESSURE GAUGE (KENT-MOORE/SPX PIN J-44680)
1. Refer to the appropriate schematic listed below and determine the correct hose to to use for the test. Then select the correct size hose barb
fitting for the tool based on the I.D of the hose. The low pressure gauge tool should be installed on the fresh air side of the canister close
valve (whenever possible).
2. Install the proper size of hose barb onto the low pressure tester. Use teflon tape (or equivalent) to insure a good seal.
3. Slide the hose clamp over the barb connector to prevent any leaks.
4. Use a bungee cord (or equivalent) to suspend or support the tool. This will prevent kinking of any system hoses.
5. Two pairs of hose pinching pliers (Snap-On part # BLC2 or equivalent) will be needed to diagnose the system.
USING THE LOW PRESSURE GAGE
NOTE 1:
DO NOT exceed 30" H20 when pressurizing the system (pressurize SLOWLY!) or the gauge will be damaged. The low pressure gauge is a
very sensitive tool.
NOTE 2:
NEVER use shop air.
NOTE 3:
NEVER pressurize the evap tester (low pressure gauge) by itself. Connect it to an evaporative emission system, or leave the 1/2" end open to
fresh air. The Mityvac (YA4OOO) can over-pressurize the evap tester in less than one stroke.
1. Use a Mityvac pump (Snap-On P/N YA4OOO or equivalent) to pressurize the system through the pressure port of the pump; connect the
Mityvac to the one-way valve.
2. SLOWLY pressurize the system up to 20" H20 (use the bleeder valve to bleed off pressure if over 20" H20). The system will "settle" (drop 3
- 7" H20) over a short period of time to equalize pressure throughout the system (see note below).
A. Vehicles with the canister at the front of the vehicle should be allowed 45 seconds for the system to settle.
B. Vehicles with the canister at the rear of the vehicle should be allowed 30 seconds for the system to settle.
Repressurize the system pressure up to 20" H20 after the "settling" has stabilized with the Mityvac pump.
3. After repressurizing the "settled" stabilized system to 20" H20, observe the gauge.
A. Steady gauge:
1. The system does not leak at current conditions. However:
a. A leak may occur from a poor sealing canister close valve*.
b. A leak may occur from a DM-TL* that isn't sealing properly internally.
c. If DT6 P0455 was set, the vehicle may have a pinched hose (blockage) in the purge line.
* The sealing ability of the canister close valve or DM-TL is not being tested using the gauge test. If the canister close valve or
DM-TL is suspected of leaking, it should be swapped with a known good unit, and the system checked with the Hi-Scan Pro.
B. If the gauge drops 2" H20 (0.07 psi) in 1 minute, a leak is present.
1. Place a set of hose pinching pliers between the one way valve and the gauge to prevent leaks past the one way valve on the
gauge.
2. Find the leak by isolating each segment from the canister (purge line, fresh air line, to-tank line, etc.).
2. Soapy water, or a listening device will help with locating the leak.
3. Leaks can also be internal to the system.
Example: a leak through the purge control valve would leak into the intake manifold, so there is no external leak that soapy
water could find. However, using hose pinching pliers before or after the purge control valve would stop the low pressure
gauge from dropping, indicating a leak at the purge valve.
USE THE HI-SCAN PRO TO ACTIVATE THE EVAPORATIVE EMISSION SELF-CHECK:
It is highly recommended to use the Hyundai Hi-Scan Pro to activate the evaporative emission self check. Using the Hi-Scan Pro will save time and
provide more consistent results. For most OBD- II Hyundai vehicles (with the exception of the 1996 Elantra), it is possible to use the Hi-Scan Pro
to activate the evaporative emissions self check in the service bay to verify repairs. "Road testing" is not practical to verify a repair for the 2000 MY
Accent, because it requires up to a 4 day time period of vehicle operation.
The self check can be found on the main menu after selecting Model and Year of the vehicle. For all vehicles except the 2000 Accent, the menu
item is labeled "Evap Leakage Test". For the 2000 Accent, the menu item is labeled DM-TL Test. Both the self checks inspect the system for leaks
'(see TSB 00-30-002 "2000 Accent Evaporative Emissions System Operation").
To familiarize yourself with the operation of the self check, remove the gas cap of a known vehicle that is operating properly and activate the self
check (follow the instructions on the Hi Scan Pro screen). With the gas cap removed, DTCs P0455, P0442 or P1443 should register after the test is
finished. Erase the code when finished, and replace the gas cap. If no code appears, turn the ignition key to off until the main power relay shuts off
and retry the process. If no code appears at this point, call the Hyundai Tech Line.
TROUBLESHOOTING TIPS
See TSB 98-30-002 for additional information and troubleshooting techniques.
P0440: A. Inspect the canister purge valve (CPV) for a mechanically

P0441: "partially open" condition. Replace valve as necessary.
P0455: A. Check for a missing/loose gas cap first.

P1443:
B. Inspect for pinched hoses in the "Purge or Tank" circuits causing a vacuum restriction to DPS.
C. Isolate the leak to the front or rear of the car (or fuel tank from canister) using the appropriate schematic to isolate components.
Apply hose pinching pliers at different locations until the source of the leak is found.
P0442: A. Isolate the leak to the front or rear of the car (or fuel tank from canister) using the appropriate schematic to isolate components.
Apply hose pinching pliers at different locations until the source of the leak is found.
B. For 1998-2000 Elantra/Tiburon with no apparent leak found, verify that the white fill vent valve plunger moves freely inside its
cage.
C. For 1998-2000 Elantra/Tiburon with no apparent leak found, verify that the canister close valve seals properly. Replace valve if
necessary.
D. For 1998 Sonata, check for a missing gas cap.
E. For 2000 Accent, inspect the canister purge valve (CPV) for a mechanically "partially open" condition. Replace valve as necessary.
1996-1997 ELANTRA/TIBURON
ENHANCED EVAPORATIVE EMISSION SYSTEM SCHEMATIC
1998-20002 ELANTRA - 1998-2001 TIBURON:

ORVR / EVAPORATIVE EMISSION SYSTEM SCHEMATIC
2001 ELANTRA
1997 DOHC/1998 ACCENT:

1999 ACCENT
200-2001 ACCENT
1998 SONATA - ALL 3.0L: 2.0L CAL SPEC ONLY:

1999 - 2001 SONATA 2.4L & 2.5L, 2001 XG 300

2001 SANTA FE
Enhanced EVAP Control System - Diagnosis And Repair

Group: FUEL SYSTEM
Number: 98-30-002
Model: ALL 1998 MODELS

Subject
ENHANCED EVAPORATIVE EMISSION
CONTROL SYSTEM DIAGNOSIS AND REPAIR
DESCRIPTION:
This bulletin provides information for 1998 model year system operation and diagnosis/repair methods for enhanced evaporative emission systems.
TABLE OF CONTENTS
New for 1998
Quick Reference Troubleshooting
Connecting the vehicle to HDS
Using the scanner to activate the EVAP Self-Check
Graph # 1: Example of 1998 Elantra Full Fuel Tank - Good Plot
Graph # 2: Example of 1998 Elantra Empty Fuel Tank - Good Plot Example of 1997 DOHC/1998 Accent Full Fuel Tank - Good Plot
Graph # 3: Example of 1996/97 Elantra Full Fuel Tank - Good Plot Example of 1997 DOHC/1 998 Accent Empty Fuel Tank - Good Plot.
Graph # 4: Example of 1996/97 Elantra Empty Fuel Tank - Good Plot
Graph # 5: Example of 1998 Elantra Too Full Fuel Tank - Inaccurate Plot
Troubleshooting and Repair (Detailed) 1998 Sonata, 1998 Elantra
Component Troubleshooting, CCV, CPV, FVV

Schematic # 1: 1998 Elantra EVAP System

Schematic # 2: 1996/97 Elantra EVAP System

Schematic # 3: 1997 DOHC/1998 Accent EVAP System

Schematic # 4: 1998 Sonata EVAP System

New for 1998 Elantra/Tiburon:

1998 vehicles introduced the On-Board Refueling Vapor Recovery (ORVR) system. ORVR is a vehicle evaporative emission control system that
captures fuel vapors during the refueling process. A new fill vent valve has been added to the system to direct the fuel vapors into the charcoal
canister. Although the system still operates in a similar manner, the canister, canister close valve and related components have been moved to the
rear of the vehicle. Only the canister purge valve remains in the engine compartment. The effect of this change is mostly seen in the HDS graphs
when an evaporative emission self check is performed. (Compare HDS graphs 1 and 2 to graphs 3 and 4 in this TSB).
Note:
Make sure the fuel tank is not completely full when performing the 1998 Elantra/Tiburon evaporative emission self check. If the fuel tank is
completely full, the HDS waveform may not be as easy to evaluate (see graph # 5).
New for 1998 Accent:

All 1998 Accents have the enhanced evaporative emission system similar to the 1996-1997 Elantra system. Previously, only the 1997 DOHC GT
Accents had the enhanced evaporative emission system. The evaporative emission system self check HDS graphs appear very similar to the
Elantra/Tiburon graphs.
New for 1998 Sonata:

1998 Sonatas have the enhanced evaporative emission system on California Certified vehicles. This system operates differently from the Elantra
and Accent engine control systems and the self check occurs under different conditions. Troubleshooting leaks requires the
"Pressurize/Clamp/Observe" method described on pages 11-14.
Note:
When connecting the 1998 Sonata to HDS, select the vehicle as California Specification. When this TSB was published, the Differential
Pressure Sensor (DPS) could only be selected when choosing the California Certified vehicle.
Quick Reference Troubleshooting

PO446:
A. Inspect the canister purge valve (CPV) as described in "canister purge valve inspection". Replace valve as necessary.
B. Inspect the "Fresh Air" circuit. Use the "Pressurize/Clamp/Observe" method to isolate a possible blockage by disconnecting hoses at different
points, each time farther from the canister.
C. Inspect the canister close valve (CCV) as described in "canister close valve inspection". Replace valve as necessary.
PO441:
A. Inspect the canister purge valve (CPV) for a mechanically "partially open" condition as described in "canister purge valve inspection".
Replace valve as necessary.
PO455:
A. Check for a missing/loose gas cap first.
B. Inspect for pinched hoses in the "Purge or Tank" circuits causing a vacuum restriction to DPS.
C. Determine whether the leak is at the front or rear of the car, and use the appropriate schematic to isolate the leak in one circuit at a time by
applying hose pinching pliers at different locations until the source of the leak is found. See troubleshooting procedure.
PO442
A. Determine whether the leak is at the front or rear of the car, and use the appropriate schematic to isolate the leak in one circuit at a time by
applying hose pinching pliers at different locations until the source of the leak is found. See troubleshooting procedure.
B. For 1998 Elantra/Tiburon with no apparent leak found, verify that the white fill vent valve plunger moves freely inside its cage.
See Fill Vent Valve troubleshooting.
C. For 1998 Elantra/Tiburon with no apparent leak found, verify canister close valve seals properly as described in "canister close valve
inspection". Replace valve if necessary.
D. For 1998 Sonata, check for a missing gas cap.

Connecting the Vehicle to HDS
To make your HDS screen appear like Graphs 1-5, follow the steps outlined below:
1. Connect HDS to the vehicle, enter "SIMU-TECH", then select "SIGNAL WAVEFORMS".
2. At the signal selection screen, select "ORDER", and then select "BY NAME". Then select "CANISTER CLOSE VALVE", "CANISTER
PURGE SOLENOID", and "DIFFERENTIAL PRESSURE SENSOR".
3. Select "OPTIONS", and select "ANALOG RECORD".
4. Select "CTRL" (control), select "MS/DIV", and then select "300 MS/DIV".
5. Select "OK", then select "RUN".
6. Start the vehicle and look at your watch (the self test occurs 16 minutes and 48 seconds after start-up).
7. After start-up, verify that the voltage for the canister close valve and canister purge valve is approximately 13.5 volts, and the DPS reads
approximately 1.6-2.7 volts depending how recently the purge control solenoid was last activated. The self check will not occur if the DPS is
below 1.6 volts. If the DPS is below 1.6 volts, stop here and perform troubleshooting procedure P0446 in this TSIB.
8. After 15 minutes, begin watching the "CAN CLOS" (Canister Close Valve) signal.
9. As soon as the canister close valve voltage drops to near zero, wait 39 seconds.
10. Touch the screen to stop recording.
11. Select "OPTIONS", then "DATA PLAYBACK".
12. Select "ZOOM", then select "-32". The screen will now look similar to graphs 1-5 on pages 6-10 of this TSB. You may have to SCROLL the
data FORWARD or BACKWARD to get the data onto your screen.
Using the HDS Digital Overlay Feature
After performing steps 1-12 to capture the self check, the digital overlay feature can be used to determine exact voltages and time frames at any
point on the waveform.
1. Select "CONTROL" then "DIGITAL", and then "OK".
2. Use the track ball to place the cursor on your starting point and click the track ball button.
3. Move the cursor to the left or to the right to analyze the data desired.
Using the Hyundai Scanner to Activate the Self-Check
For 1997 Elantra, 1997 Tiburon, and 1997 DOHC Accent, scanners with cartridge V1.8 can be used to activate the self check anytime after the
vehicle reaches operating temperature. However, the scanner will not activate the self check for 1996 and 1998 vehicles at this time.
1. Set up and run HDS as described earlier in steps 1-5.
2. Make sure the vehicle is at normal operating temperature, there are no DTC codes present (clear any codes before performing the check), and
the O2 sensor is in Close Loop.
3. If all conditions are met, start the Evap Check and the scan-tool will display "Now Trying to Trigger Evap Test". A few seconds later
"Waiting For Evap Test To End" is displayed.
4. Approximately 30 seconds later, the message "Evap Test Complete" will be displayed. Wait about 10-15 seconds to stop the HDS recording
(continue with steps 10-12, under Connecting the Vehicle to HDS).
Enhanced Evaporative Emission Troubleshooting
Perform the following to inspect the system for leaks:
Note 1:
The procedure described below assumes that all electrical connections are in good condition.
Note 2:
A "test" hose should be made from an 18 inch (457.2 mm) length of 3/8 inch (9.53 mm) fuel hose to perform most of the diagnostic procedures.
Note 3:
Two pairs of hose pinching pliers (Snap-On part # BLG2 or equivalent) will be needed to help troubleshoot the system.
1. Referring to the appropriate schematic, connect and clamp the "test hose" to the following hose in the system:
1998 Sonata:
The hose is located between the canister and the two way valve (Photo 1 - Left, rear of vehicle).
1998 Elantra/Tiburon:
The hose is located between the canister and the canister close valve (Photo 2 - Left, rear of vehicle).
Note:
For 1998 Elantra/Tiburon, the fuel tank must not be completely full to perform the following procedure. If the fuel tank is completely full,
the waveform may not be as easy to evaluate.
1996/97 Elantra/Tiburon
1997 DOHC/1998 Accent
The hose is located between the canister air filter and the canister close valve (Photo 3 - Left, front, inner fender of vehicle).
2. a. Connect HDS to the vehicle, enter"SIMU-TECH", then select "SIGNAL WAVEFORMS".
b. At the signal selection screen, select "ORDER", "BY NAME" and then "DIFFERENTIAL PRESSURE SENSOR".
c. Select "OPTIONS" and select "DIGITAL RECORD".
d. Select "OK" and then select "RUN".
e. Set the ignition switch to the "ON" position.
f. While watching the DPS signal on HDS, GENTLY begin to blow into the fuel hose with approximately 1.0 psi (the DPS voltage
should begin to rise). Continue to gently blow into the hose until the DPS voltage is approximately 4.0 volts.
Do not over pressurize since the sensor cannot read over 4.7 volts.
3. a. When the DPS reads approximately 4.0 volts, immediately clamp the "test" hose with hose pinching pliers (see Photo 4).
b. In a good system, the voltage will remain steady or even rise slightly if the canister is at the rear of the car (the value must remain
constant: +/- 0.05 volts over 10 seconds). If the voltage drops, go to step E. If the voltage remains steady, go to step C.
c. By removing the hose pinching pliers, the system should return to atmospheric pressure (2.5 +/- 0.2 volts) within 25 seconds. If the
voltage takes longer than 25 seconds to return to 2.5 +/- 0.2 volts, go to step D. If the voltage returns in less than 25 seconds, go to step
J.
d. If it takes longer than 25 seconds, check for restricted vapor hoses or internal blockages in the "to tank" circuit. Correct any conditions
found. Repeat step 2.
e. If the DPS voltage decreases after clamping, a leak is present in one of the circuits or at the canister. Isolate the leak into either the
Purge, Tank or Fresh Air circuits. Use the procedure outlined below.
f. Pressurize and clamp as described in steps 2 and 3a, and connect a second set of hose pinching pliers at the "to tank" vapor hose on the
canister. If the voltage drops, go to step G. If the voltage remains steady, go to step 1.
g. Pressurize and clamp as described in steps 2 and 3a, and connect a second set of hose pinching pliers at the "purge" vapor hose on the
canister. If the voltage drops, go to step H. If the voltage remains steady, go to step 1.
h. Inspect the canister for a small leak by clamping both the "purge" and "to tank" vapor hoses, and supplying a low pressure source
(approximately 1 psi) into the fresh air nipple, while spraying the canister with soapy water. If a leak is found, replace the canister. If
no leak is found, repeat procedure starting at steps 2 and 3a.
i If the DPS voltage remains steady after the second set of hose pinching pliers are clamped, then the leak is on the other side of the
"clamped" circuit. Pressurize and clamp as described in steps 2 and 3a, each time moving the second set of hose pinching pliers farther
away from the canister, but in the same circuit until the leak is found. The "test hose" connection may have to be moved to different
areas when checking the "to tank" circuit. Use the schematic to try to keep the DPS in the system when pressurizing and observing for
leaks.
j. If no apparent leak is found, thoroughly check the "fresh air" circuit and the canister close valve as described in "canister close valve
inspection".
Caster Close Valve Inspection
Cycle the CCV several times using a test lead connected to a 12 volt battery source. Gently blow through the top nipple with low pressure
(approximately 1 psi) and check for a small leak. At 1 psi, no air should pass through the valve.
Warning:
Blowing more than 1 psi through the top of the valve can push the valve seal off the seat giving the appearance of a leak, and blowing into the
side nipple will push the seal onto the seat, masking a potential leak.
Canister Close Valve Locations
1996-97 Elantra/Tiburon:
1997 DOHC/1998 Accent:
Left, Front Inner Fender
1998 Elantra/Tiburon
1998 Sonata:
Left, Rear behind Fuel Tank

Canister Purge Valve Locations
All Elantra/Tiburon:
Left, Front Strut Tower Near Brake Master Cylinder
All Accent:
Left, Front Strut Tower Under Fuse Box

Canister Purge Valve Inspection
1. Remove the CPV and blow through it in both directions. Without it being energized, the valve should not allow air to pass through it.
Replace the valve if necessary.
2. Check for an intermittent condition. Cycle the CPV several times using the test lead by connecting it to a 12 volt battery source. Disconnect
the power source and blow through it again in both directions. Without it being energized, the valve should not allow air to pass through it.
Replace the valve if necessary.
3. "Tee" in a vacuum gauge on the "canister" side of the CPV. With a good valve, vacuum is "0" when the CPV is not cycling. The gauge will
pulse when it starts to cycle. Touch your hand on the CPV to verify when it stops cycling; the gauge should read "0" vacuum when the valve
is not cycling. If the gauge reads any amount of vacuum when it is not cycling, the valve is stuck open and needs replacing.
Fill Vent Valve Inspection
Remove the Fill Vent Valve from the fuel tank enough to see that the white valve plunger is in the "open" position and moves freely up and down.
If the white valve plunger is stuck "up" in the closed position, the fuel fill vent valve assembly will need to be replaced.
Fill Vent Valve Location:
1998 Elantra/Tiburon:
Top, rear center of fuel tank

Normal warranty diagnosis and repair operation codes and times apply.Technical Service Bulletin # 02-30-001 Date: 021201
Emissions - EVAP Leak Code Diagnosis/Repair

Group
30 - FUEL SYSTEM
Number
02-30-001
Date
12-2002
Model
All Models
Subject:
ENHANCED EVAPORATIVE EMISSION CONTROL DIAGNOSIS AND REPAIR FOR P0442, P0446, P0455 AND P1443 LEAK CODES
USING A LOW PRESSURE GAUGE
DESCRIPTION:
This TSB is an addendum to TSB 00-30-003. Technicians already familiar with TSB 00-30-003 will benefit from the new diagnostic tree. Several
revisions are embedded into the diagnostic tree, and a summary of the revisions are shown. New technicians can start with the diagnostic tree and
refer to TSB 00-30-003 for additional information.
INTRODUCTION:
By pressurizing a sealed evaporative emission system, the pressure leakdown rate can easily be measured using a low pressure gauge. The system
should be slowly pressurized to a very low pressure (in this case 20" H20) . A properly operating system (one that does not leak) will not lose any
pressure; in fact, with high fuel temperature and high ambient temperature, pressure may increase due to fuel vaporization. A very small leak is read
as a 2" H20 drop of pressure over one minute.This tool is intended to verify and diagnose evaporative emission leaks with Diagnostic Trouble
Codes (DTCs) P0456, P0442, P0455, P0457, and P1443. In some instances DTCs P0446, P0440 and P0441 can also be diagnosed.
Low Pressure Gauge Tool (L.P.G.T.) - SPX EVAP Tester P/N J-44680 Tips for using the low pressure gauge.
1. Pressurize evap system to 20" H20 for testing.
2. Never use shop air, or pressurize beyond 30" H20.
3. Always use teflon tape or sealer on the hose barb connection.
4. Use a hose clamp over the connection hose.
5. Use hose pinching pliers to clamp off sections to isolate the leak.
6. Use a bungee cord (or equivalent) to support the tool to prevent kinked hoses.
Summary of revisions from TSB 00-30-003:
1. Fuel caps must NOT be tightened or adjusted prior to performing the leak check.
A. Fuel caps that are loose due to improper installation by the customer are not warrantable. A loose fuel cap is not a result of a "defect in
factory material or workmanship".
2. Fuel level must be below 1/4 to perform the low pressure leak check. The ideal condition is with low fuel light on.
3. The pressure tester tool should be pinched with hose pinching pliers (such as Snap-on P/N BLC2 or equivalent) between the one way valve
and the pressure release valve.
4. Pipe thread sealer must be used on the hose barb connection of the pressure gauge.
5. Canister close valve or DM-TL replacement should only be performed after proper pressure checking.
Schematic Diagram Index

1996-1997 ELANTRA/TIBURON
1998-2000 ELANTRA - 1998-2001 TIBURON

2001-2003 ELANTRA
2003 ELANTRA
2003 TIBURON
1997 DOHC/1998 ACCENT

1999 ACCENT
2000-2003 ACCENT
1998 SONATA - ALL 3.0L; 2.0L CAL SPEC ONLY

1999-2003 SONATA 2.4L, 2.5L, 2.7L / 2001 XG300, 2002-2003 XG350

2001-2003 SANTA FE
Exhaust System - Excessive Sulfur Odors

Number: 05-20-004
Date: JULY, 2005
Model: ALL MODELS
Subject
SULFUR ODOR FROM EXHAUST
DESCRIPTION:
Some vehicles may experience a sulfur-like or "rotten egg" odor coming from the exhaust. The amount of sulfur in the fuel sold in California is
regulated; however, the sulfur content in gasoline sold in other states can be significantly higher. Sulfur content can differ considerably between
gasoline brands and locations. Sulfur is a natural component of crude oil from which gasoline is refined. The amount of sulfur in gasoline can be
reduced through the refining process.
VEHICLES AFFECTED:
^ All Models
REPAIR PROCEDURE:
A sulfur odor coming from the exhaust does not necessarily indicate there is an issue with the engine's running condition. A sulfur odor most likely
is related to the fuel; however, if an excessive sulfur odor is determined, perform the following steps:
1. MIL ON - Check for diagnostic trouble codes (DTCs) and repair as necessary.
2. If no DTCs are found, recommend the customer to try an alternate gasoline source.
Replacement of the oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the odor and will not be considered warrantable.
Normal warranty procedures apply, only if the concern is found to be a defect in factory workmanship or materials.
HDS Scan Tool - Part Numbers.

Group: SPECIAL SERVICE TOOLS
Number: 98-09-001
Model: ALL
Subject
HDS SCAN TOOL PART NUMBERS
This TSB revises TSB # 97-09-002 and contains updated part number information
DESCRIPTION:
A list of replacement part numbers for the HDS Scan Tool are shown. To order any of the items listed, contact Kent-Moore at 1-800-345-2233.
J-41490-C Hyundai Scanner (complete with all items listed)
J-4149-1 Scanner Unit
J-41490-3 Expansion Slot Cover
J-41490-5 Data Cable
J-41490-6 Cigarette Lighter Power Cable
J-41490-7 Battery Power Cable
J-41490-8 VT 100 Cable
J-41490-9 Carrying Case
J-41490-10 Hyundai 2 Adapter
J-41490-12 OBD-II Adapter
J-41490-13 VT 100 HDS Adapter
J-41490-15A Software Cartridge (includes '98 update chips)
J-41490-16 Empty Replacement Plastic Cartridge (includes only

J-41490-15A label)
J-41490-98 Software Cartridge Update kit (1 version 1.8 chip)
J-41490-K5A Personality key

J-41490-INST Instruction Manual
* Bolding denotes new or updated part numbers.

HDS Scan Tool - Loaner Program

Number: 98-09-003
Date: APRIL, 1998
Model: ALL
Subject
HDS SCAN TOOL LOANER PROGRAM
This TSB revises TSB # 95-09-003, and contains updated part number information
DESCRIPTION:
Hyundai has arranged with Kent-Moore to provide a loaner HDS Scan Tool if your unit should need repair during the warranty period.
If you experience a problem with the Hyundai Diagnostic Scan Tool, it is important to initially contact the Hyundai Technical Assistance Line
(1-800-325-6604) to verify the need for repair.
If the Hyundai Technical Assistance Line refers you to Kent-Moore, please contact their customer service department at 1-800-345-2233.
Your dealership will be charged the price of the HDS Scan Tool. Upon return of the complete loaner to Kent-Moore, your dealership will be
credited the price of the loaner.
The loaner unit consists of the following:
J-41490-1 Scanner Unit

J-41490-3 Expansion Slot Cover
J-41490-5 Data Cable
J-41490-6 Cigarette Lighter Power Cable
J-41490-9 Carrying Case
J-41490-10 Hyundai 2 Adapter
J-41490-12 OBD-II Adapter
J-41490-K5A Personality Key
J-41490-INST Instruction Manual

Scan Tool Software - Update Information

Number: 98-09-004
Date: APRIL, 1998
Model: ALL
Subject
SCAN TOOL SOFTWARE UPDATE INFORMATION (VERSION 1.8)
DESCRIPTION:
This TSB describes the 1998 Scan Tool Software Package (V1.8) along with the following additional information to assist with Scan Tool
operation:
^ Helpful Notes and Tips for Scan Tool "No Communication"
^ Using the Evaporative Emission System Trigger Test
^ Scan Tool part numbers
^ Scan Tool warranty labor operation codes
1998 SCAN TOOL SOFTWARE UPDATE (V1.8):
The new 1998 Scan Tool software update contains the following improvements and additions:
^ 1998 vehicle database
^ Evap system trigger for 1997 vehicles for use with Hyundai Diagnostic System (HDS) (this will save the Technician from waiting for the 15
minute pre-cycle time). See this TSB for complete instructions.
^ Updated diagnostic code (DTC) descriptions for easier understanding.
^ Data display uses "Custom Data" menu only. (Encourages Technician to select only the relevant component data to be displayed, resulting in
improved data refresh rates.)
^ Removed "Connect OBDII Connector..." message for faster performance.
^ Improved accuracy of data readings.
^ Checks for proper GCI chip. (The GC1 chip is the other chip on the cartridge circuit board that must be at version 1.1. Communication errors
would occur if the proper GC1 chip is not installed.)
NOTES AND TIPS FOR USING THE SCAN TOOL:
A. If a "No Communication" message is displayed on the HDS Scan Tool when trying to view codes or data, check/try the following items:
^ Check for correct Vehicle Identification Number (VIN). Be careful when entering a 1997 or 1998 VIN and answer the "Tiburon?"
question correctly,
^ Clean the contacts of the K5A Personality Key with Hyundai Multi-Purpose Cleaner & Degreaser or another suitable contact cleaner, A
film or residue from the shop environment may form on the Personality Key contacts causing poor circuit connection. Results may be
erratic communication or no communication at all.
Note:
Many SRS system communication conditions are solved by cleaning the K5A Personality Key. However, if cleaning the K5A Personality Key
contacts does not work, a replacement key may be necessary. Call Kent-Moore at 1-800-345-2233 to order a new K5A key (P/N J-41490-K5A).
^ SRS communication conditions can occur when the main SRS fuse is blown. The SRS light may be on, however, the module does not
have power and cannot communicate with the Scan Tool.
^ Secure data link connection - Check OBD-II adapter and vehicle data link connector pins for damage. (Tweaking of OBD-II adapter pins
approximately 10 degrees may help.)
^ Turn the ignition key OFF and back ON. This re-sets the Powertrain Control Module (PCM) communication system.
^ In some cases, for older model vehicles (pre-1996), it may be necessary to attempt communication by selecting one year above or one
year below the model year being worked on as the software in the Scan Tool can only accommodate one communication setting per
model configuration.
^ Re-enter the VIN and make sure the key is in the ON position and not the ACC position.
B. Codes should only be cleared with the ignition in the ON position. If the engine is running, the codes may not be cleared properly.
C. If the plastic cartridge housing is cracked or damaged, an empty replacement plastic cartridge (P/N J-41490-16) (includes the label) can be
ordered through Kent-Moore. (See this TSB for more information and Scan Tool part numbers.)
D. A new Scan Tool adapter is available that contains an extra plastic strip to allow a more secure connection to the data link connector.
Using the Evaporative Emission System Trigger Test

The Evaporative Emission System Trigger Test works best in combination with HDS and is found in the "Select Systems" menu on the Scan Tool.
1. Set up the HDS as you normally would to monitor the Evap System by selecting from the "Signal Waveforms" screen the Canister Close
Valve, the Canister Purge Valve and the Differential Pressure Sensor (DPS). Set the MS/DIV (millisecond/division) to 300.
2. Make sure the vehicle is running at normal operating temperature, there are no codes present (clear any code before performing test) and the
oxygen sensor is active.
3. If all conditions are met, start the Evaporative Emission Test and the Scan Tool will display "Now Trying to Trigger Evap Test". After a few
seconds "Start Recording on the HDS System" message will display. At this point click the RUN button on HDS to start recording.
4. About 30 seconds later the message "Wait about 10 seconds then stop recording on the HDS System" will be displayed. After 10 seconds,
stop the recording on the HDS. The HDS should have captured the Evaporative Emission System cycle. If the Evap Test did not perform as
described above, disconnect and then re-connect the scan-tool before attempting to perform the Evap Test again.
Note:
i) After performing the Evap Test, it may be necessary to cycle the key off and back on to view engine codes and data. This resets the
powertrain control module (PCM) communication system.
ii) The Evap Test can only be performed twice during one key on cycle. Turn the engine off and wait about 15 seconds before trying to run the
test again.
Scan Tool Part Numbers

Shown is a list of replacement part numbers for the HDS scan tool. To order any of the items listed, contact Kent-Moore at 1-800-345-2233.
Engine Performance - Misfire Code Diagnosis

Number: 99-36-014
Model: ALL OBD II VEHICLES
Subject
MISFIRE CODE DIAGNOSIS
This Technical Service Bulletin supersedes 97-90-012. Please discard the old TSB and replace it with this new one.
TABLE OF CONTENTS
* A Guide To Repairing Misfire Codes
* ECM Misfire Detection Methods
* Diagnostic Trouble Code Definition
* Customers Description of the Symptom
* Scan Tool Data
* Ignition Wires
* Dielectric Grease
* Spark Plug Tubes
* Spark Plug
* Ignition Coil
* Fuel Quality
* Fuel Injectors
* Cylinder Leakage Testing
* Cylinder Leakage Testing Versus Compression Testing
* Lubricating Oil System
* Hydraulic Lash Adjusters
* Cylinder Head Bolt Torque
* Crank Angle Sensor and Crankshaft Tone Wheel
* Coolant Temperature Sensor and Intake Air Temperature Sensor
* Oxygen (02) Sensor
* Rough Road (Acceleration) Sensor
* Cylinder Head Assembly
* Misfire Diagnosis Worksheet
A GUIDE TO REPAIRING MISFIRE CODES

Please read through this entire bulletin before using any portion of this repair guide. All terms, components and specific procedures are described in
the main body of this TSB.
ON THE 1ST REPAIR ATTEMPT:

Record misfire codes. Choose the most appropriate category from the four (4) selections below:
1. One cylinder has a misfire code (see procedure A)

2. Paired misfire codes as described below (see procedure B)
- Cylinders 1 and 4 or cylinders 2 and 3 (4 cylinder engines)

- Cylinders 1 and 4 or cylinders 2 and 5, or cylinders 3 and 6 (V6 engines)
3. Multiple cylinders have misfire codes, and/or there is a random misfire code (see procedure C)
4. Misfire code (one or more) occurs only on cold start-up (see procedure D)
Procedure A (One cylinder misfire code)

1. Mist spark plug wires and check for arcing.
2. Remove spark plugs and check for evidence of carbon tracking.
3. Perform cylinder leakage (leak-down) test.
A. If leakage is less than 10%, continue to step 4.
B. If leakage is 10% or greater, remove the head to perform valve job. (See specifics in cylinder head section).
4. Replace spark plugs. Lightly apply dielectric grease to the spark plug wire tip/boot base.
5. If misfire is in cylinder #4 (P0304) on Elantra or Tiburon, loosen and retorque the M12 cylinder head bolts to 26 ft-lbs + 60 ° angle +
60° angle.
6. In the misfiring cylinder, swap injector with another cylinder.
Procedure B (Two misfire codes that are coil paired; Cylinders 1 and 4 or cylinders 2 and 3 (4 cylinder engines); Cylinders 1 and 4 or cylinders 2
and 5, or cylinders 3 and 6 (V6 engines))

2. Remove plugs and check for evidence of carbon tracking.
4. If leakage is less than 10%, continue to step 4.
5. If leakage is 10% or greater, remove the head to perform valve job. (See specifics in cylinder head section).
6. Replace the coil.
Procedure C (Multiple cylinders misfire codes, and/or a random misfire code)
1. Check LT (LongTerm) fuel trim. If over 10%, check fuel pressure.

2. Check AFS calibration against known good value.
3. Check for proper operation of EGR and purge control valve.
4. Mist spark wires and check for arcing.
5. Remove spark plugs and check for evidence of carbon tracking.
7. Check fuel sample from the inlet (bottom side) of the filter to check for the presence of water or contamination.
8. Check intake air supply for evidence of oil in the air cleaner or on the AFS.
9. Tweak pins on AFS and TPS (TSB 96-36-003)
Procedure D (Misfire codes occurs only on cold start-up)
1. Check oil level and viscosity for evidence of "thick" oil.

2. Check for after market oil filter (no bypass valve).
4. Remove plugs and inspect for carbon tracking.
6. Check oil pressure against established standards. Service relief valve, orifice plug, or replace case to correct excessive oil pressure situation.
7. Replace hydraulic lash adjusters.
NOTE: 2nd and all subsequent repair attempts Call the Hyundai Technical Assistance line at (800) 325-6604. Be prepared to answer the questions
on the Misfire Diagnostic Worksheet. You may be asked to fax a completed copy of the worksheet to expedite the diagnosis / repair process.
ECM MISFIRE DETECTION METHOD

It can be tough to hear or feel a misfire, which is one reason why new emissions-control standards require the on-board diagnostics (OBD-II) of the
engine control module (ECM) to monitor each cylinder for misfire.
Engine misfire detection is based on the difference of engine rotational speed between the firing cylinders and the missing cylinder. When a
cylinder is misfiring, it takes a "longer time" for the crankshaft to rotate to the next cylinder in the firing order. This "time" is measured by the
crankshaft angle sensor (CAS) which measures the actual rotational travel of the crankshaft in real time. This information is evaluated by the ECM.
If the misfiring cylinder took "longer" to rotate the crankshaft than the other cylinders, the ECM will set the appropriate diagnostic trouble code
(DTC) for that cylinder. As an example; an inline 4 cylinder engine's crankshaft rotates 1800 as each cylinder fires through the firing order. In a
properly running engine with a firing order of 1-3-4-2, the time between the firing of 1-3 will be the same as 3-4, 4-2, and 2-1. In an engine that has
a misfire in cylinder #2; it takes the crankshaft longer to travel through the 2-1 firing rotation.
The repair of today's misfire is more difficult than pre-OBD-II vehicles because the ECM is programmed to detect the slightest change of
crankshaft rotational speed. The criteria for detecting a misfire is set by the Federal Government and all vehicles sold in the U.S. must comply with
these requirements. The engine management system must be able to perform three critical elements of misfire detection:
1. Monitor, identify and if severe enough, illuminate the "check engine" light for a misfiring cylinder;
2. Set separate diagnostic trouble codes for multiple cylinders;
3. During a misfire great enough to damage the catalyst, the "check engine" light must blink.
DIAGNOSTIC TROUBLE CODE DEFINITION
P0300 - Misfiring in more than one cylinder, but unable to detect the specific cylinder because the misfire is random.
P0301 - Misfire in cylinder number 1 is very likely.

CUSTOMER'S DESCRIPTION OF THE SYMPTOM

The customer information plays a significant roll in misfire diagnosis. The customer should be asked the following questions.
1. Is there a driveability or performance issue?

- Has the car been in before for the same condition? Can it be duplicated?
- How often?
- Under what conditions?
* Use this information to verify any corrective action performed.
2. When did the "check engine" light illuminate?

- At start up?
* If cold engine, see Hydraulic Lash Adjuster Section.
* If warm engine, all items should be considered.
- While driving at operating temperature?

* All items should be considered.
3. How does the customer typically drive the vehicle?

- Short trips in the city?
NOTE: This can set a misfire code due to poor combustion leading to excessive carbon deposits.
- Long highway trips?

4. Did the "Check Engine" light blink or remain illuminated?

- Blinking light indicates misfire is severe enough to cause catalytic converter damage.
* Check fuel injector section.
- Steady light.
5. Does the car experience excessive oil usage?

- This can set a misfire code due to poor combustion leading to excessive carbon deposits.
Diagnostic Procedure
SCAN TOOL DATA
Use the Hyundai Scan Tool to retrieve DTC codes and freeze frame data. Any Diagnostic Trouble Codes other than misfire codes must be repaired
before attempting to correct the misfire code(s). Retrieving scan tool freeze frame data can be just as valuable as the customer's information. Engine
operating conditions at the time the DTC was set can indicate what system to inspect. A vehicle that misfires on initial start-up may indicate a
problem with oil pressure and/or hydraulic lash adjusters. Ensure that the Coolant Temperature Sensor, Intake Air Temperature Sensor, Air Flow
Meter, and Long Term Fuel Trim are reading normal values (when compared to a known good car).
IGNITION WIRES
Inspection Before Removal

Before removing the wires from the spark plugs, mist the exteriors of the wires and boots with water and look for arcing of the spark plug wires
with the engine running. Or, in a similar check, ground a heavy (16 gauge) jumper wire, connect it to the shaft of an insulated screwdriver, and idle
the engine. Then drag the screwdriver tip lightly over each plug wire, watching for sparks jumping from the wire to the screwdriver shaft. After
removing the wires, they can be measured with an ohmmeter. Resistance should be approximately 4000 Ohms (4K ~) per foot. If the car has a
distributor ignition, lift the cap and touch one lead of the ohmmeter to the terminal inside, the other to the terminal in the plug boot. Spark plug
wires will usually set a specific cylinder DTC code (i.e. P0301, P0302 etc.).
When removing plug wires from the spark plugs, you must use spark plug pliers. Twisting the boot to break the heat seal often is necessary, even
when using the pliers. Never try to pull on the plug wire itself. You may cause a separation (open) in the resistance wire, or at the terminal end.
Route The Wires

Always duplicate the factory routing of the plug wires. The guides are there to ensure the separation necessary for the high-voltage to follow its
intended path. Also the guides assist in reducing the affects of electromagnetic interference on the standard 5v to 12v electrical/electronic systems.
Dielectric Grease
Before installing the spark plug boot onto the spark plug, smear a thin film of Permatex Dielectric Tune-Up Grease (or equivalent) to the following
three locations:
1. Terminal stud at top of the spark plug
2. Around the tip of the spark plug boot (just inside the opening)
3. At the bottom of the spark plug boot (on the terminal connector)
The dielectric grease helps prevent any voltage leakage from the terminal stud to the metal shell of the spark plug. Do not attempt to "waterproof"
the spark plug boot by filling the boot with dielectric grease. This can prevent the terminal inside the boot from locking onto the spark plug terminal
stud.
Spark Plug Tubes

A common cause of misfires is moisture accumulation in the spark plug tubes. Engines like the 1.8/2.0 Elantra/Tiburon and 2.0L Sonata may hold
moisture after engine degreasing/cleaning. Moisture can cause a phenomenon described as a "Corona Discharge" (see spark plug section). Problems
caused by water in the spark plug tubes can be cured by removing the moisture and applying a little dielectric grease as described earlier. Moist
spark plug tubes will usually set a specific cylinder DTC code (i.e. P0301, P0302 etc.).
Spark Plugs
If you have a misfire, there's a fair chance a spark plug is the cause. Although plugs won't lead-foul with today's unleaded gasoline, they can
oil-foul, carbon-foul or even be fouled by some fuel additives. Look for excessive oily-black or sooty carbon-black deposits. Causes of deposits
include oil entering the combustion chamber past the valve stem seals or piston rings, an overly rich fuel mixture, continuous low speed driving, a
spark plug that has too cold of a heat rating, or deterioration of the ignition system. Spark plugs will usually set a specific cylinder DTC code (i.e.
P0301, P0302 etc.).
A "Corona Discharge" is a phenomenon that occurs in a humid environment, or when the insulator surface is dirty (see photo's). This condition
occurs if an electrical charge builds-up and there is moisture in the air (or spark plug tube) or the plug has a dirty insulator. The worst case result is
a flash-over spark from the metal shell to the terminal stud. A result of the discharge is carbon tracking.
A. Ionization is building on the porcelain at the top of the metal shell (seen as a pale blue light);
B. The ionization is creeping up the porcelain insulator.
C. Flash-over occurs when/if the ionization reaches the terminal stud.
Photo: Corona Stain caused by oil particles in the air that are attracted to the corona discharge. The corona stain causes no deterioration to the
function of the spark plug; however, any moisture adhering to the porcelain or the stain will cause flash-over
Carbon tracking (see photos) not only builds on the spark plug, it can also leave carbon deposits on the inside of spark plug boot. If carbon tracking
is found, replace spark plugs and ignition wires in sets.
Ignition Coil
When misfires occur in paired cylinders (ie. P0301 and P0304; or P0302 and P0303 for inline four cylinder engines), the coil should be inspected
using HDS to verify the signal waveform, or swapped with a known good coil to see if the misfire codes travel to the other cylinders. Two
examples of how properly operating and malfunctioning coils appear are shown below.
- The above example shows the ignition signal viewed on HDS. Firing duration on Coil 2 & 3 indicates the coil is functioning properly
(test with engine as operating temperature
- HDS plot for Coil 1 & 4 shows an insufficient firing duration.
Fuel Quality
Fuel quality concerns usually appear as multiple cylinder or random misfire codes. A sample of the fuel should be taken from the bottom of the fuel
filter. Inspect the fuel for traces of water by using a test kit, or by letting the fuel "settle out". If water and/or contamination is found, replace the
filter and inspect the fuel tank for water or corrosion. If no water or contamination is found, install a new filter as contamination in the fuel tank is
not likely. Additionally, if large amounts of very fine rust are found in the fuel filter, fuel tank and at the fuel injectors, replacement of components
between the injectors and fuel tank may be required. Fuel quality will usually set a random misfire code (P0300) and/or specific cylinder DTC
codes (i.e. P0301, P0302 etc.).
Fuel Injectors
Fuel injectors can be checked by swapping locations of the suspect injector to another cylinder and checking if the misfire code travels with it. Fuel
pressure and fuel pressure bleed down should also be inspected. Fuel pressure at idle must be 35-39 psi with the vacuum hose connected to the fuel
pressure regulator. With the vacuum hose disconnected from the fuel pressure regulator, the pressure should rise to approximately 42-46 psi. Fuel
pressure must not bleed down for 5 minutes (after the initial settling that occurs when the engine is turned off). After 20 minutes, the pressure must
remain above 25 psi. If rust is found at the fuel injectors and fuel tank, replacement of components between the injectors and fuel tank may be
required. Fuel injectors will usually set a specific cylinder DTC code (i.e. P0301, P0302 etc.).
Cylinder Leakage Testing

Performing a cylinder leakage (leak down) check should not be confused with performing a compression check. A cylinder leakage check measures
the rate at which air leaks past the valves, rings, head gasket, cylinder wall, etc. Cylinder leakage equal to or below 10% is considered acceptable.
Leakage greater than 10% in any one cylinder indicates valves/seats or piston rings need attention. This tool can also help locate the source of the
leakage by listening for the escaping air. Listen in these areas to help determine the condition:
1. Oil dipstick tube - for worn cylinder walls or broken/worn rings.

2. Radiator cap - for cylinder wall crack or head gasket leakage (will be seen as air bubbles).
3. Adjacent cylinder - for head gasket leakage.
4. Exhaust pipe - for exhaust valve leakage.
5. Throttle body - for intake valve leakage.
NOTE: Some leakage will always occur past the piston rings. Experience will be required to discern "normal" amounts of leakage.
To save time, the leakage check can be performed when the spark plugs have already been removed from the engine. The leakage check should be
performed with a warm engine, but cool enough to remove the spark plugs without damaging the threads in the cylinder head (removing spark
plugs out of a hot engine with aluminum cylinder heads will damage the threads). Follow the manufacture's instructions for specific tool usage.
Cylinder Leakage Testing Versus Compression Test

A compression test is a tool to check "general" engine condition which will compare cylinders to each other and/or to a published specification. The
limit to this test is that there are too many variables. Variables such as cam profile, engine cranking speed etc., will affect the readings. At best, a
compression test can determine a specific cylinder problem and possibly separate valve from ring problems.
A cylinder leakage test will provide the same data a compression test provides, but the leakage test will be more accurate and pinpoint where the
leak is coming from.
Lubricating Oil System

The lubricating oil system should be inspected for "thick oil", "thin oil", or evidence of sludge build up. "Thick oil" also causes high oil pressure
because it is difficult to make the oil flow (high viscosity) through the engine. Oil with too high a viscosity may not flow into the hydraulic lash
adjusters properly causing them to collapse. "Thin oil" that is diluted by fuel or other substances or just the wrong viscosity for the ambient
temperature can cause low oil pressure. Oil that is too thin can bleed down too fast in the hydraulic lash adjuster and cause ticking noises. Particle
formation in a "sludged-up" engine can enter the valve-train and block oil feed passages to hydraulic lash adjusters (see TSB# 98-20-002). This
causes low oil pressure at the hydraulic lash adjusters and can cause them to collapse, thus causing improper valve opening and timing, leading to a
misfire. Conversely, high oil pressure can over extend hydraulic lash adjusters causing a loss of compression, leading to a misfire.
Oil pressure should be measured with the engine at operating temperature, with a gauge connected at the oil pressure sensor port. Typical oil
pressure reads 10-20 psi at idle (depending on the vehicle), and 35-45 psi at 2000 rpm (depending on the vehicle). If the oil pressure is too high or
low and the oil and filter have been changed, inspect the oil pressure regulator at the oil pump for a possible stuck open or stuck closed condition.
For Elantra and Tiburon engines, there's a check valve located in the cylinder block near the cylinder head deck. The check ball should be able to
move freely in its "cage". The check valve also acts as an orifice so that the cylinder head receives less pressure at the head than at the main
bearings.
Cylinder head bolts must be tightened in the proper sequence, and to the specified torque value. Cylinder heads that are improperly torqued can lead
to cylinder head gasket leakage between cylinders. Be sure to follow the specification in each shop manual for proper torquing of the cylinder head
bolts. The 1996-1999 Elantra-Tiburon engine and the 1999 2.5L V6 Sonata engine use the "torque-angle" method to clamp the cylinder head to the
cylinder block. The "torque-angle" method involves torquing the fastener to a predetermined starting torque, then tightening the fastener to the
additional angle(s) published in the shop manual. Use Snap-On Torque Angle Gauge P/N TA362 (or equivalent) to aid in determining the proper
angle to tighten the fasteners to.
Hydraulic Lash Adjusters

Hydraulic lash adjusters are sensitive to oil pressure and oil viscosity. As discussed in the lubricating oil section, oil pressure that is too high will
cause the lash adjuster to over extend, and oil pressure that is too low will cause the lash adjuster to collapse. If the oil is too viscous (thick), it may
not enter into the lash adjuster causing a collapsed lash adjuster.
In some cases, the lash adjuster bore in the cylinder head can become distorted and mechanically bind up the lash adjuster. The lash adjuster should
always move freely in its bore. An example of this is on the 1.8/0LOL engine used in the Elantra and Tiburon. The number four cylinder has an
M12 cylinder head mounting bolt located next to one of the intake valve lash adjuster bores. It the cylinder head bolt is overtorqued, it causes the
lash adjuster bore to distort, thus binding the lash adjuster. This can hold a valve open long enough to lose compression in the cylinder and cause a
misfire. This condition may not show up in a leak down test or compression test, but should be visually inspected if a P0304 code is stored.
Cylinder Head Bolt Torque
Crank Angle Sensor and Crankshaft Tone Wheel

The crank angle sensor (GAS) and crankshaft tone wheel work together to provide the ECM top dead center (crankshaft position) information. The
tone wheel is mounted to the crankshaft and rotates with the crank. The GAS is mounted 0.020 - 0.059" from the tone wheel. As the tone wheel
rotates past the GAS, the signal appears as shown in graphs 1 & 2 on HDS. Large voltage "drop-outs" can be an indicator of a loose or damaged
tone wheel causing random and specific misfire codes (P0300, P0301, P0302 etc.).
A loose tone wheel can quickly be checked while the GAS is removed from the engine. Use a long, narrow, flat blade screwdriver to push, pull
and/or by on the tone wheel through the GAS hole. Any movement of the tone wheel indicates its loose. The tone wheel is mounted to the
crankshaft with four screws.
Coolant Temperature and Intake Air Temperature Sensor

The Hyundai scan tool should be used to measure the engine coolant temperature and the intake air temperature. When the engine is cold, both
values should be near the ambient temperature. When the engine reaches operating temperature, verify that the coolant temperature reads higher
than the intake air temperature. This check rules out any possibility that the wire harness connectors might have been inadvertently switched, or that
there is a faulty sensor.
Oxygen (02) Sensor

If any misfire code is accompanied by an oxygen sensor code, repair the oxygen sensor code before attempting to repair the misfire code. Oxygen
sensors that malfunction can cause excessive carbon in the cylinders, thus causing a misfire. If the carbon build-up is verified, consider the top
engine cleaner treatment before proceeding with repairing the misfire code. Refer to TSB 97-36-004 for proper diagnosis of the oxygen sensor.
Rough Road Sensor (Acceleration Sensor)

The rough road sensor (acceleration sensor) is used to interpret road conditions that may make the engine move in its engine mounts. Unexpected
movement of the engine block relative to the crankshaft will cause a misfire if the rough road sensor is not operating. If the vehicle is driven on a
very rough road, the sensor will send the ECM a signal to inhibit misfire monitoring. The Elantra, Tiburon and Accent all use sensors mounted on
the shock tower. The 1999 Sonata uses information from the wheel speed sensor at the right front wheel to determine a rough road.
Cylinder Head Assembly

Removal of the cylinder head should only be performed after the ignition, fuel, and engine management systems have been eliminated as possible
causes of the misfire code(s). Removal of the cylinder head should only be done when cylinder leakage is suspected past the valves. Before
removing the cylinder head, visually check the valve springs to see if any are broken, the valve keepers to see if any are missing, the lifter bores for
distortion or scoring, and the intake and exhaust ports for any debris holding the valves open. Also, check the intake and exhaust ports for signs of
oil leakage past the valve stem seals.
After the above inspections are made, the cylinder head should be ready for removal. The cylinder head should be left as a sub-assembly (valves,
springs, retainers, and keepers) and sent to a competent, professional machine shop for the following:
- Replace all valve guides and ream guide inner diameter to establish correct guide to valve fit
- Cut valves at 46°
- Cut the seats with a "three angle" cut (30°, 45°, 60°), aiming to the minimum published seat width specification
- Measure valve spring tension and replace out of spec springs
- Measure the installed height of the valve spring
When the finished head is returned from the machine shop, it may be necessary to bleed the hydraulic lash adjusters so as not to bind the camshaft
during installation. As a final check before installation, fill the combustion chamber (or intake and exhaust ports) with solvent and wait 5 minutes.
The solvent should not bleed past the valves. If it does leak, the cylinder head should be returned to the machine shop for corrective measures.
MISFIRE DIAGNOSIS WORKSHEET Technical Service Bulletin # 01-00-002 Date: 011001
Hi-Scan Tool - Software Update Using A PC

Group: GENERAL
Number: 01-00-002
Date: OCTOBER, 2001
Model: ALL
Subject
UPDATING THE HI-SCAN USING A PC
WITH INTERNET ACCESS
DESCRIPTION:
You can update your Hi-Scan using a Personal Computer (PC) with Internet access.
The website is www.hmaservice.com. On this web page, locate and select Hi-Scan Updates. Then select Latest Software. You will then be at the
Latest Hi-Scan Software Upgrades page. Scroll down and find Hi-Scan Utilities. You will need to install this software on your PC in order to
communicate and apply the System and Reprogramming software to your Hi-Scan.
HI-SCAN UTILITIES INSTALLATION INSTRUCTIONS:
1. Right click on "Hi-Scan Utilities" and select "open".
2. A File Download screen will pop up. Select "Run this program from its current location" and then click "OK".
3. After several minutes, the Program will begin to install onto your machine.
NOTE:
A Security Warning Message may appear stating "Do you want to install and run Hi-Scan Utilities.exe from www.hmaservice.com" after step 3.
If so, click the "Yes" button.
4. A Welcome screen will pop up. Click "Next".
5. A User Information screen will pop up. If not already typed in, you may type your name and company name and click "Next".
6. A Choose Destination Location screen will pop up. The installation program will notify you of the installation directory. Do not change the
location of the default installation directory. Click "Next".
7. A Select Program Folder screen will pop up. The installation program will notify you of the Program Folder in which you will find the
program after installation. Click "Next".
8. A Start Copying Files screen will pop up. The installation program will list the Current Setting for your installation. Click "Next".
9. You will see the installation process. Once complete, select "Yes, Launch the Program File". Click "Finish" to complete Setup.
NOTE:
If you choose to run the program later, click "Finish". Do not select "Yes, Launch the Program File". To access the Program File later, click on
Start (at the bottom left hand corner of your monitor), then Programs, then Hi-Scan Utilities and finally HSUtilities.
10. See TSB 00-00-001 for complete instructions on updating Hi-Scan software cards. Technical Service Bulletin # 98-90-002 Date:
980201
Keyless Entry Upgrade Kit - Door Solenoid Defect

Number: 98-90-002
Model: ALL
Subject
SECURITY SYSTEM KEYLESS ENTRY UPGRADE KIT: DOOR SOLENOIDS
DESCRIPTION:
Some Hyundai Security System Keyless Entry Upgrade kit door solenoids may have their internal wiring reversed. When the Keyless Entry
Upgrade Kit is installed and activated, the door(s) may lock when it should unlock and vice versa.
If the Keyless Entry Upgrade Kit meets the following two conditions:
1. The door solenoid's plastic housing is tan colored and

2. The Keyless Entry Upgrade Kit was ordered from your local Parts Distribution Center (PDC) before December 31, 1997, it may be necessary
to reverse the connection of the door solenoid's red and blue wires to achieve the correct function.
SERVICE PROCEDURE:
1. Install the Keyless Entry Upgrade Kit to the point of making the connection of the door solenoid wires.
2. Temporarily connect the door solenoid wires and check the function of the door locks by arming and disarming the security system. If the
door locks function in reverse (that is, if they lock when they should unlock and vice versa), reverse the red and blue wires at the door
solenoid connection to achieve proper function.
3. Continue with the installation per directions from the Upgrade Kit.
Windshield WIper Blade - Service Procedure

Number: 98-90-004
Date: MARCH, 1998
Model: ALL
Subject
WINDSHIELD WIPER BLADE INSERT SERVICE PART
This TSB supersedes TSB # 98-60-002
DESCRIPTION:
If the windshield wiper blades do not effectively clean the windshield, the windshield wiper blade inserts may need to be replaced.
This bulletin provides a procedure for replacement of the windshield wiper rubber blade in the wiper blade assembly.
REPLACEMENT PROCEDURE:
The wiper blade assembly is composed of 3 parts: clip, frame and rubber blade. The rubber blade contains 2 rail springs in its body.
1. Remove the wiper blade assembly from the wiper arm. Depress the removal tab on the clip and slide the wiper blade assembly off of the
wiper arm.
2. Locate the groove at the lower end of the rubber blade. Confirm the groove is at the same end as the removal tab in the clip (see illustration).
3. Flex the rubber blade at the groove lower end to expose one of the rail springs.
4. Remove the two rail springs (one at a time) by pulling them parallel to the rubber blade.
5. Separate the grooved end of the rubber blade from the frame by twisting the grooved end area of the rubber blade.
6. Slide the rubber blade insert out of the frame.
7. Confirm the Insert direction of a new rubber blade (refer to the position of the removal tab in the clip).
8. Insert the new rubber blade into the frame from the upper end of the rubber blade, following the insert direction.
9. Twist the grooved end of the rubber blade to fit the groove into the frame.
10. Slide the spring rails into the slots on both side of the rubber blade, making sure to seat them fully on both ends.
11. Reinstall the wiper blade assembly to the wiper arm. Check that the rubber blade is secure in the frame and the wiper assembly cleans the
glass effectively.
PARTS INFORMATION:
Please note that windshield wiper rubber blades are covered under warranty for 12 months or 12,000 miles.
A/T - End Clutch Retainer/Plate Modifications

Group: TRANSAXLE
Number: 97-40-032
Date: OCTOBER, 1997
Model: ALL
Subject
END CLUTCH RETAINER AND CLUTCH PLATE MODIFICATION
DESCRIPTION:
The thickness of the automatic transaxle end clutch plates has been increased to improve the durability of the end clutch. The end clutch retainer
and transaxle case were modified as shown to accommodate the change in clutch plate thickness.
EFFECTIVE VEHICLE PRODUCTION DATE:

PARTS INFORMATION:
INTERCHANGEABILITY:
SP-II Automatic Transaxle Fluid

Group: TRANSAXLE
Number: 98-40-010
Model: ALL
Subject
SP-II AUTOMATIC TRANSAXLE FLUID
DISCUSSION:
SP-II ATF has been used as a factory fill for Hyundai automatic transaxles since the production dates shown below. Previously, type 7176 ATF
was used as a factory fill.
VEHICLE EFFECTIVE DATE
Accent, Elantra 9/16/95

Sonata 2.0L and 3.0L 9/23/95
Tiburon ALL
SP-II is blended to a different specification than type 7176. It has a different additive package and was designed to give ideal friction characteristics
to the new transaxles used by Hyundai. The benefits of SP-II are:
^ The low temperature shifting characteristics of the transaxle have been improved, due to the low temperature characteristics of SP-II.
^ The chemical stability and oxidation resistance of SP-II has been improved, which allows a longer maintenance interval.
MAINTENANCE INTERVAL:
The maintenance interval for the ATF and the filter has been changed as follows:
Severe Usage is defined below:
^ Repeated short distance driving.
^ Driving in dusty, rough or sandy areas.
^ Driving in mountainous areas.
^ Extensive idling.
^ More than 50% driving in heavy city traffic during hot weather above 90°F (32°C).
^ Driving in areas where salt or other corrosive materials are used.
^ Driving in very cold weather.
^ Towing a trailer.
PARTS INFORMATION:
ATF PART NUMBER TYPE ATF
PREVIOUS 00212-11100 TYPE 7176

NEW 00230-18000 SP-II
NOTE:
The previous ATF is no longer available from the Hyundai Parts System. Only SP-II ATF will be provided to Hyundai dealers in quart bottles.
INTERCHANGEABILITY:
For 1996-99 vehicles, use only SP-II ATF
For 1986-95 vehicles, use either type 7176 or SP-II ATF Type 7176 and SP-II ATF can be mixed in any proportion. If type 7176 ATF is used, or
type 7176 and SP-II ATF are mixed, the previous maintenance interval must be followed. Technical Service Bulletin # 00-40-004 Date:
000301
Remanufactured Automatic Transaxle - Inspection

Number
00-40-004
Group
TRANSAXLE
Date
MARCH, 2000 Model
Subject
VISUAL INSPECTION OF
REMANUFACTURED AUTOMATIC TRANSAXLE
Model:
ALL
DESCRIPTION:
Before replacing an automatic transaxle with a remanufactured unit, it is critical that the technician perform a "30 second walkaround" comparison
of the two units. This quick inspection will ensure that the replacement transaxle is fully compatible with the original unit.
INSPECTION:
Prior to installation, carefully compare the two transaxles, looking especially at the following:
1. Torque converter - ring gear location (stepped versus flush), number of bolts and bolt thread pitch
2. Solenoid and temperature sensor connectors - flush connector or extension harness and number of pins
3. Kickdown servo switch - electrical connector configuration

4. Range switch - connector configuration and number of pins
The inspection should be conducted whenever a transaxle is replaced to confirm that the transaxle is compatible, prior to attempting installation.
NOTE: If an incorrect transaxle has been ordered and not installed or damaged, your Parts Department may return it to the PDC through DCS
using the new 45-day BC Return Program.
If an incorrect transaxle has been installed or damaged, it must be returned to the remanufacturer. Please write "ordered in error" or "damaged" in
the space for the old ATM serial number on the "Core Return Checklist".
A/T - Remanufactured A/T Program

Group: TRANSAXLE
Number: 01-40-004
Model: ALL
Subject:
REMANUFACTURED AUTOMATIC TRANSAXLE (ATM) PROGRAM
THIS TSB HAS BEEN REVISED TO CHANGE THE ALLOWABLE REPAIRS.
DESCRIPTION:
The automatic transaxle warranty repair policy has been revised to authorize in-dealership repairs of the following components for both OEM and
remanufactured automatic transaxles:
NOTE:
Do not replace the automatic transaxle to service the condition and components listed. Instead, repair/replace the components according to the
related shop manual or TSB.
If an internal ATM mechanical condition is diagnosed, remove and replace the ATM with a remanufactured unit. No internal disassembly of the
ATM should be performed. ATM internal overhauls require DPSM prior approval/authorization.
NOTE:
Second and subsequent remanufactured ATM replacements on the same VIN will require Tech Line (800/325-6604) approval/authorization
prior to repair and DPSM approval/authorization for claim payment.
TRAINING:
The Automatic Transaxle Troubleshooting and Certification Course (# 451300) provides detailed instructions on how to properly diagnose and
when to repair or replace an ATM. DPSM approval is necessary when installing remanufactured transaxles it your dealership does not currently
employ a technician who has attended this course.
AFFECTED MODELS:
This program applies to all models except 1986 Excels.

^ Hyundai Transmission Cooler Flush (aerosol), P/N 00235-18100
^ Hyundai Automatic Transaxle Testers: A/T Tester (Kent-Moore # J39853) and ATM Tester II (Kent-Moore # 09450-AT000)
^ HDS and HDS Trans-Tech Module (DDC-Trans Module)
^ Hi-Scan Pro (Kent-Moore # J44410) and HDS Scan Tool (Kent-Moore # J41490)
Diagnosis Procedure
1. The Service Advisor opens a Repair Order (R.O.) documenting the customer's detailed comments. A road test by a technician or Service
Advisor may be necessary to verify the customer's description.
2. The Service Advisor carefully completes the top section of the ATM Diagnosis Worksheet.
3. The ATM Diagnosis Worksheet (P/N NP150-07006) and shop copy of the R.O. are dispatched to the technician. (The remaining copies of
the R.O. can be broken out and distributed according to established dealership procedures.)
4. The technician follows the Diagnostic Flow Chart on the back of the Worksheet to help complete the diagnosis of the ATM and to make a
repair/replace decision.
5. If it is determined that a remanufactured unit must be ordered and installed, the technician must obtain the Service Manager's approval and
signature on the Worksheet.
6. The technician sends both the Worksheet and the R.O. to the Parts Department.
7. The Parts Department orders a remanufactured ATM from the facing PDC and retains the R.O. and Worksheet, filed by R.O. number.
8. The Parts Department receives a remanufactured ATM, shipped prepaid in a reusable box, and provides the ATM to the technician.
NOTE:
Retain the reusable box and use to return the removed ATM and torque converter to the remanufacturing center.
A complete package of forms is included with each remanufactured ATM unit as shown below:
^ Core Return Checklist
^ Pre-addressed shipping label
^ Bill of Lading
9. The Parts Department completes all required fields of information on the Core Return Checklist. Failure to do so will result in a debit.
10. The technician completely drains all fluids and removes the ATM and torque converter from the vehicle.
NOTE:
11. Flush the transaxle oil cooler and hoses using Hyundai Transmission Cooler Flush (P/N 00235-18100). Follow instructions in TSB #
98-40-004.
12. Install the remanufactured ATM according to the appropriate shop manual. Fill the ATM to the specified level with Genuine Hyundai SPII
(P/N 00230-18000) or SPIII (P/N 00230-11000).
13. Secure the removed torque converter to the removed ATM using the torque converter retaining strap and bolts removed from the
remanufactured ATM.
14. Install all plugs removed from the remanufactured ATM onto the removed ATM before packaging to prevent residual fluid from leaking.
15. Place the top copy of the and ATM Diagnosis Worksheet and the top copy of the Core Return Checklist in the plastic bag provided with the
remanufactured ATM and close the envelope securely. Ensure both forms are completely filled out.
NOTE:
Failure to properly complete and/or return the designated Core Return Checklist and ATM Diagnosis Worksheet will result in a $50.00
reduction of the core credit and/or chargeback of your warranty claim.
16. Place the removed ATM into the shipping container provided with the remanufactured ATM. Secure the lid with the retaining straps.
17. Attach the address label provided with the remanufactured ATM and ship the removed ATM with the ATM Diagnosis Worksheet and Core
Return Checklist.
NOTE:
Freight charges are paid by HMA for returning the removed ATM to the remanufacturing center, if the enclosed bill of lading is used and the
ATM is shipped via HMA approved carriers. DO NOT SUBMIT A WARRANTY CLAIM FOR THESE CHARGES.
18. Retain the bottom copy of the Core Return Checklist in the dealership's Parts Department, filed by the repair order number indicated in the
top right hand corner of the checklist.
19. Retain the canary copy of the ATM Diagnosis Worksheet together with the shop copy of the R.O. in the dealership's VIN service files. The
dealership must record the removed and remanufactured ATM serial numbers on the shop copy of the R.O.
20. The remanufacturing center receives the removed ATM, Core Return Checklist and ATM Diagnosis Worksheet.
21. The remanufacturing center checks the documents and sends the forms to HMA.
22. The dealer is reimbursed for the core ATM.
NOTE:
Second and subsequent ATM reman replacements on the same VIN will require Tech Line (800/325-6604) approval/authorization prior to the
repair and DPSM approval/authorization for claim payment.
NOTE:
If an incorrect transaxle has been ordered and not installed or damaged, you may return it to the PDC through DCS using the new 45-day BC
Return Program.
If an incorrect transaxle has been installed or damaged, it must be returned to the remanufacturer. Please write "ordered in error" or "damaged"
in the space for the old ATM serial number on the "Core Return Checklist".
NOTE:
HMA may deny/chargeback all portions of ATM claims and/or core credits on remanufactured units if:
^ Cooler not properly flushed~ causing damage to the remanufactured ATM to fail
^ Remanufactured ATM damaged due to:
^ Improper handling
^ Improper installation/removal
^ Improper packaging
^ No trouble found/incorrect diagnosis
^ Comeback repair/incorrect diagnosis
^ Incomplete or missing Core Return Checklist and/or ATM Diagnosis Worksheet
NOTE:
NOTE:
Dealer Parts Department accepts full responsibility for ensuring that transaxles sold over the counter:
^ Have an ATM Diagnosis Worksheet that is completely and accurately filled out
^ The ATM oil cooler is flushed to HMA specifications using Hyundai Transmission Cooler Flush (P/N 00235-18100)
^ Genuine Hyundai transmission fluid SPII (P/N 00230-18000) or SPIII (P/N 00230-11000) is used to refill the ATM.
A/T - 2-3 Shift Flare or Shift Shudder

TITLE: AUTOMATIC TRANSAXLE 2-3 SHIFT FLARE OR SHIFT SHUDDER
APPLIES TO: ALL
SERVICE TIP:
If you are servicing a vehicle with 2-3 shift flare (engine speed increases during the 2-3 shift) or shift shudder, follow the procedure shown
below:
1. CHECK ATF LEVEL:
^ Attach a Hi-Scan Pro and select "Automatic Transaxle" and "Current Data" menus and "Oil Temperature Sensor".
^ Drive the vehicle until the ATF temperature is at normal operating temperature (158-212°F or 70-100° C).
^ Place the shift lever in "Neutral" and check the ATF level on the dipstick.
Add SPIII ATF to bring the level to the top of the "FULL" mark.
2. CHECK FOR APPLICABLE TCM REPROGRAMS AND MODIFIED ATM:

3. CHECK FOR MODIFIED TCMS:
4. CHECK TRANSAXLE OIL TEMPERATURE SENSOR:
^ Attach the Hi-Scan Pro to the DLC and select "Hyundai Vehicle Diagnosis" and "Automatic Transaxle" menus. Check "Temperature Sensor"
when the ATF is cold and hot. If the oil temperature sensor does not indicate as shown below, replace the sensor:
5. DISCONNECT THE BATTERY AND PERFORM ADAPTIVE LEARNING:
^ Drive the vehicle until the ATF temperature is above the temperature shown.
^ Accelerate the vehicle through several 1-2-3-4 upshifts at small throttle openings (approximately 25-30% TPS) until shift flare or shift
shudder no longer occurs.
6. TEST DRIVE THE VEHICLE.
^ If the above procedures have been completed and shift flare or shift shudder continues to occur, replace the transaxle.
A/T - Reman A/T Installation Precautions

TITLE: ATM Installation
APPLIES TO: All
SERVICE TIP:
Remanufactured transaxles are shipped with a retaining strap to hold the torque converter in place. Do not remove the strap until the transaxle is
mounted on the transmission jack and ready for installation.
If the torque converter has moved from the fully inserted position, carefully push inward and rotate the torque converter until the converter is
recessed approximately 1/2"-3/4" into the transaxle case.
NOTE: If the converter is not fully seated as shown, the oil pump will be damaged and the vehicle will not move after installation.
M/T - Transaxle Removal and Installation

Group
40 - TRANSAXLE
Number
03-40-011
Date
06-2003
Model
ELANTRA 1996-2003, SANTA
FE 2001-2003, SONATA 1996-2003
AND TIBURON 1997-2003
Subject
TRANSAXLE REMOVAL AND INSTALLATION
SERVICE PROCEDURE FOR THE PULL TYPE
CLUTCH SYSTEM
DESCRIPTION:
This bulletin provides a service procedure for the removal and installation of manual transaxles with the "pull" type clutch system.
"Pull" or "push" type clutch systems refer to the direction of operation to disengage the clutch relative to the flywheel. In a "pull" type clutch
system, the release bearing is attached to the clutch cover fingers and "pulls" the clutch cover away from the clutch disc (away from the flywheel),
disengaging the clutch.
VEHICLES AFFECTED:
All 1996 Model Year and newer vehicles equipped with manual transaxles except Accents which have the "push" type clutch system.
SERVICE PROCEDURE:
1. Drain the transaxle gear oil.
2. The reference photo shows the clutch related components as viewed from outside the transaxle case.
3. Loosen the release lever nut and washer.
4. Separate the release lever by removing the snap pin and clevis pin.
5. Separate the release lever from the fork shaft.
6. Loosen the bolts attached to the release cylinder and separate the release cylinder from the transaxle assembly (no need to open the clutch
hydraulic system).
7. Remove the transaxle assembly after removing each bolt attached to the engine assembly.
8. Remove the clutch cover assembly. The release bearing is still attached.
9. To separate the release bearing from the clutch cover, rotate the release bearing to gain access to the bearing snap ring.
10. Insert the snap ring pliers under the wave washer to release the bearing.
11. Replace the clutch components as necessary by following the steps in the appropriate Shop Manuals.
NOTE
Do not attach the new release bearing to the clutch cover.
12. Install the release bearing on the fork as shown.
13. Attach the clutch cover without the release bearing to the flywheel while the clutch disc is aligned using the clutch disc guide tool (refer to
the appropriate Shop Manuals for the clutch disc guide tool part number).
14. Attach the transaxle assembly to the engine assembly.
NOTE
Make sure not to apply any side loads to the clutch components.
15. Install the release lever on the release fork shaft by aligning notches (release lever attaches only one way on the shaft).
16. After completing step 15, pull the release lever to engage the release bearing into the clutch cover fingers. If there is a click sound, the release
bearing and the clutch cover are aligned correctly. If the assembly does not click and snap into place, the release bearing and the clutch cover
are not aligned correctly. Repeat steps 13, 14 and 15.
NOTE
Do not apply excessive force on the release lever to engage the release bearing.
17. Reconnect all removed components in the reverse order of removal.
18. Add the specified amount and type of oil into the filler hole (refer to the applicable Shop Manuals for this information). Technical Service
Bulletin # 03-40-015 Date: 030801
A/T - 2nd - 3rd Gear Shift Flare/Shudder

Group
TRANSAXLE
Number
03-40-015
Date
AUGUST, 2003
Model
ALL
Subject
AUTOMATIC TRANSAXLE 2-3 SHIFT FLARE OR SHIFT SHUDDER
DESCRIPTION:
If you are servicing a vehicle with 2-3 shift flare (engine speed increases during the 2-3 shift) or shift shudder, follow the procedure shown below:
1. CHECK ATF LEVEL:
^ Attach a Hi-Scan Pro and select "Automatic Transaxle" and "Current Data" menus and "Oil Temperature Sensor".
^ Drive the vehicle until the ATF temperature is at normal operating temperature (158-212°F or 70-100°C).
^ Place the shift lever in "Neutral" and check the ATF level on the dipstick. Add SPIII ATF to bring the level to the top of the "FULL"
mark.
2. CHECK FOR APPLICABLE TCM REPROGRAMS AND MODIFIED ATM.
3. CHECK FOR MODIFIED TCMS.
4. CHECK TRANSAXLE OIL TEMPERATURE SENSOR:
^ Attach the Hi-Scan Pro to the DLC and select "Hyundai Vehicle Diagnosis" and "Automatic Transaxle" menus. Check "Temperature
Sensor" when the ATF is cold and hot. If the oil temperature sensor does not indicate as shown, replace the sensor:
5. DISCONNECT THE BATTERY AND PERFORM ADAPTIVE LEARNING:

^ Drive the vehicle until the ATF temperature is above the temperature shown.
^ Accelerate the vehicle through several 1-2-3-4 upshifts at small throttle openings (approximately 25-30% TPS) until shift flare or shift
shudder no longer occurs.
6. TEST DRIVE THE VEHICLE.
^ If the above procedures have been completed and shift flare or shift shudder continues to occur, replace the transaxle.
Spark Plug Wire - Routing, Manual Addition

Number: 98-36-004
Date: JUNE, 1998
Model: 1992-95 ELANTRA

1992-98 2.0L SONATA
Subject
DOHC SPARK PLUG WIRE ROUTING (SHOP MANUAL ADDITION)
DESCRIPTION:
The 1992-95 Elantra and 1992-97 Sonata Shop Manuals do not contain the spark plug wire routing.
The cylinders are numbered in ascending order (1-2-3-4) from the front to the rear of the engine. The coil is "grouped" into two sections, 1-4 and
2-3. The wiring arrangement on the coil, starting from the upper most secondary terminal, is 4-1-2-3.
Please record this information in the appropriate shop manuals and write down this TSB number for future reference.
A/T - Intermittent Delayed, Erratic, Harsh Shifting

Group: TRANSAXLE
Number: 98-40-002
Date: APRIL, 1998
Model: ALL
Subject
PULSE GENERATOR DIAGNOSIS
This TSB revises TSB # 97-40-025-1 to provide additional diagnosis procedures
DESCRIPTION:
The following conditions may be caused by an improperly functioning pulse generator. The conditions may be intermittent and difficult to
duplicate.
^ Delayed or erratic 1-2 shift, with engine hot or cold
^ Harsh 1-2 shift
^ Harsh 2-1 downshift, at a higher speed than the normally scheduled downshift
^ Erratic downshift during light acceleration
^ Third-gear "fail-safe condition and/or "Check Engine" light on
^ Bucking and/or hesitation
The following diagnostic codes (DTC) may be stored in memory in the transaxle control module (TCM):
OBD II NON-OBD II DESCRIPTION
P0717 31 and/or 81 No pulse generator-A signal

P0722 32 and/or 82 No pulse generator-B signal
Note 1:
For Non-OBD II vehicles, always check the "Transaxle" menu in the HDS Scan Tool for additional codes.
Note 2:
The following DTCs may be induced by an incorrect output of the PG-B and do not necessarily indicate a mechanical condition in the transaxle.
P0732 A/T 2nd gear ratio problem

P0733 A/T 3rd gear ratio problem
P0734 A/T 4th gear ratio problem
P1624 MIL- On request from TCM
After repairs are made to the pulse generator, clear the codes and test drive the vehicle for two driving cycles*. If the DTCs do not return, the codes
were induced by the incorrect output of the PG-B.
* A driving cycle is defined as:
^ The engine is started cold (coolant at ambient temperature)
^ The coolant temperature rises to 160°F
^ The fuel system goes into closed loop. (To determine closed loop, attach the HDS Scan Tool to the data link connector (DLC), select
"Engine", "Codes and Data" and "Data" menus and monitor "Fuel Sys1" until the readout is "CL")
SERVICE PROCEDURE:
1. Disconnect the pulse generator connector.

2. Using small needle nose pliers, gently twist the male pins in the pulse generator main connector approximately ten (10) degrees clockwise to
ensure electrical contact.
3. Reconnect the pulse generator connector.
4. Remove the connector from the transaxle mounting bracket. Leave the connector loose on the transaxle case to prevent any tension on the
harness.
5. Verify the correct operation of the pulse generator according to the procedure shown.
A. Connect the HDS Scan Tool to the DLC.
B. From the Menu, select "4-Speed Trans", "Codes and Data" and "Data".
C. Drive the vehicle at a steady speed in third gear with the overdrive switch off while an assistant monitors PG-A and PG-B. Check that
both PG-A and PG-B are approximately equal to the engine rpm in third gear. If so, the pulse generators are functioning properly.
Engine - Oil Consumption Test Procedure

Number: 03-20-001
Model: ALL
Subject
OIL CONSUMPTION TEST PROCEDURE
DESCRIPTION:
The following information and procedure is provided to assist you in documenting and verifying excessive oil consumption.
An engine that is operating properly will use some amount of oil. A thin oil film is responsible for lubricating the cylinder walls and preventing
premature ring and cylinder wear. This oil film is consumed during the combustion process and the amount consumed can add up over many hours
of engine operation.
Engine oil usage will vary based on many factors including ambient temperature, engine size, quality and viscosity of oil, and driving habits.
The first 1,200 miles are very important for the engine to break in and engine oil usage may be slightly greater during this time period. The oil
consumption test (outlined below) should not be performed on a vehicle with less than 1,200 miles.
TEST PROCEDURE:
1. Check the oil level on the dipstick and record the reading. Change oil and filter under the normal maintenance procedure. Note the condition
of the oil. Does it look like the oil has been changed at the proper intervals?
2. Arrange with the customer to visit the dealership every time the engine needs oil for the duration of the test. At every visit, the oil
consumption sheet must be filled out including mileage, date, amount of oil added and the technician's initials. For a proper diagnosis, the
amount of oil consumed over a known mileage should be checked three times and then averaged.
The accumulated mileage divided by the total amount of oil added will give the consumption rate in miles per quart (see example below). If
the oil consumption rate is greater than 1000 miles per quart, further diagnosis may be required.
Charging System - Diagnosis

Number: 99-36-009
Date: JULY, 1999
Model: ALL
Subject
CHARGING SYSTEM DIAGNOSIS
TSB OUTLINE:
DIAGNOSTIC FLOW CHART
I. GENERAL INFORMATION
(1) INITIAL CHECKS:
A) Check Battery Condition
i) Visual Inspection
ii) Load Test
iii) Three Minute Charge Test
B) Check Generator Belt
C) Check Fuses & Wiring/Connector Condition
D) Static Current Draw Check
E) Pre-Excitation Resistor (or relay)
II. CHARGING SYSTEM TESTS
(1) CIRCUIT RESISTANCE TEST:
A) Using DVOM
B) Using VAT-40 (or equivalent)
i) Circuit Resistance Test
ii) Insulated Circuit Resistance Test
iii) Ground Circuit Resistance Test
(2) GENERATOR CURRENT OUTPUT TEST:
A) Using DVOM and Ammeter

(3) VOLTAGE REGULATOR TEST:
A) Using DVOM and Ammeter
i) Voltage Regulator Test
ii) Diode Stator Test
DIAGNOSTIC FLOW CHART
The flow chart is provided as a suggested approach to efficiently diagnose a charging system.
I. General Information
The charging system consists of the following components:
^ Generator (with a built-in rectifier and voltage regulator).
^ Battery.
^ Charging system wiring.
^ Charging indicator light (in the instrument cluster) and associated wiring.
^ Pre-Excitation Resistor.
The generator has eight built-in diodes. These diodes convert the AC output of the generator into DC output (rectified).
All Hyundai generators have an internal voltage regulator. The regulator is part of the brush holder unit. The function of the voltage regulator is to
control the output voltage of the generator to prevent excessive voltage from being applied to the vehicle's electrical system.
CHARGING SYSTEM SCHEMATIC (TYPICAL)
A. Check Battery Condition

i) Visual Inspection:
1. If the battery has vent caps, check the electrolyte level. It should be above the top of the plates or at the indicated level within the cells.
Add distilled or mineral free drinking water to raise the electrolyte level. Do not overfill.
2. Check for loose or corroded terminals and connectors. A solution of baking soda and water will clean most corrosion from the battery.
3. Inspect the battery case and cover for cracks and other physical damage.
4. Inspect the battery for electrolyte leakage.
5. Inspect for a loose or damaged hold-down.
NOTE:
If the battery shows any type of damage that cannot be cleaned or repaired, replace it.
ii) Load Test Procedure:
The following procedure utilizes a Volt Ampere Tester, (VAT-4O or equivalent) to perform the Load Test Procedure.
1. Connect the test leads as show in the figure.
NOTE:
Insure the battery is fully charged prior to conducting a load test.
2. Apply a 15O-170 amp load to the battery.
3. Maintain this load for 15 seconds while watching the voltmeter Turn off the control knob immediately after 15 seconds.
4. The voltage should not fall below 9.6 volts while the load is applied.
5. After the load is removed, recovery voltage should be a minimum of 11.2V.
NOTE:
If the voltage falls below 9.6 volts while the load is applied, conduct the Three Minute Charge Test.
iv) Three Minute Charge Test:
A three-minute charge test will determine if the discharged battery can be recharged or should be replaced. If the battery is to be tested in the
vehicle, disconnect both battery cables to avoid damaging the generator and electrical system. If high voltage is recorded early in the test,
stop the test and replace the battery. High internal resistance due to sulfation on poor internal connections will develop heat that can boil the
electrolyte.
1. Connect the charger leads to the battery terminals, observing correct polarity (+) lead to (+) terminal and (-) lead to (-) terminal.
2. Connect a voltmeter across the battery, (+) lead to (+) terminal and (-) lead to (-) terminal.
3. Turn the charger on and adjust it for the highest charging rate but not exceeding 40 amps for a 12 volt battery. If the charger has a
timer, set it for 3 minutes.
4. After 3 minutes, read the voltmeter with the charger charging. If it is 15.5 volts or less, the battery can be safely recharged. If it exceeds
5.5 volts, the battery should be replaced.
B. Check Generator Belt

Visual Inspection:
1. Check the belt surface for damage, peeling or cracks.
2. Check the belt for worn or hardened areas.
3. Check the belt to make sure it fits properly into the pulley grooves.
Belt Tension Test:
The recommended way to check belt tension is with a tension gauge.
"Type A" Tension Gauge
1. Place the hook between two cogs of the belt.
2. Do not let the dial section of the tension gauge contact other objects during measurement.
3. Read the tension value on the dial and compare the reading to Hyundai specifications below.
MODEL HYUNDAI SPECIFICATION

ALL 100 +/- 20 lbs. (45.5 +/- 9.1kg)
NOTE 1:
Always take two or more readings, moving the belt each time.
NOTE 2:
If a tension gauge is not available, apply a pressure of 20-22 pounds (88.96-97.86N) to the belt. If the belt can be deflected more than 1/2 inch
(12.7 mm), the belt will require tightening.
C. Check Fuses & Wiring/Connector Condition

Inspect all system wiring and connections. When connectors become loose, damaged, or corroded, they may cause high resistance in a
circuit. High resistance causes excessive voltage drop, which may cause improper operation of system components.
Make sure that any multiple plug connectors are latched correctly. Make sure that all connections in the charging circuit are making good
electrical contact.
The main connections to check are:

1. Both ends of the battery cables.
2. Generator terminals.
3. Fusible links, connections at the fuse box and fuse box link.
D. Static Current Draw Test

This test should be performed if you suspect excessive current draw from the battery.
1. Make sure that all warning lamps are off, all doors are fully closed and that the ignition key is turned "OFF" and the key is removed
from the ignition.
2. Disconnect the negative battery cable.
NOTE:
When the battery is disconnected, any Diagnostic Codes (DTC) stored in the engine control and transaxle control modules (ECM &
TCM) will be lost. In addition the clock and radio will have to be reset.
3. Connect the ammeter in series between the negative battery terminal and the negative battery cable.
4. The ammeter will measure the static current draw
5. If the static current draw is above 25mA, isolate and repair the cause of the current draw
E. Pre-Excitation Resistor (or Relay)

The generator produces electricity by creating a magnetic field in the stator & rotor. When a vehicle is first started, this magnetic field must
be initiated (pre-excitation). Once the initiation has started and the generator begins producing output with sufficient voltage (more than
battery voltage), the generator provides self-excitation. Thus, the pre-excitation circuit (including the pre-excitation resistor/relay) is only
required during the generator output initiation phase.
If the pre-excitation resistor malfunctions, the pre-excitation circuit may not function properly and generator initiation may not occur, in
which case, the generator will have no output. Thus, if a generator has no output, swap the pre-excitation resistor/relay with a known good
unit and check again for output in order to confirm or eliminate the pre-excitation circuit as a possible cause.
Location of the pre-excitation resistor:

Vehicle Location
Accent (SOHC) On the dash panel near the centerline of the vehicle
Elantra/Tiburon In the engine compartment fuse box
Sonata (V6 & 14) On the dash panel on the passenger side above the brake booster
B. Test Procedure Using Sun Volt Ampere Tester

(VAT-40 or equivalent):
i) Circuit Resistance Test:
1. Set TEST SELECTOR knob to # 2 CHARGING position.
2. Set LOAD INCREASE knob to the OFF position.
3. Set VOLT SELECTOR knob to the EXT 18 V position.

4. Connect tester leads as shown in the figures.
5. Start the engine and increase to 2000 RPM.
6. Adjust LOAD INCREASE knob until the reading of the Red Ammeter Scale indicates 175 A.
7. Observe the reading on the Green Voltmeter Scale. Note this reading.
8. Set VOLT SELECTOR knob to INT 18 V position. Observe the reading on the Green Voltmeter Scale. Subtract this reading
from the reading obtained in step 7. The difference is the voltage drop caused by circuit resistance and must be less than 0.5
volts.
NOTE:
If the voltage drop exceeds 0.5 volts, then conduct the test on the following page (Insulated Circuit Resistance Test).
ii) Insulated Circuit Resistance Test:
NOTE:
Leave main clamps on VAT-40.
1. Connect test leads as shown.
2. Set VOLT SELECTOR knob to EXT 3 V position.
3. Start the engine and adjust speed to approximately 2000 RPM.
4. Adjust LOAD INCREASE knob until Red Ammeter Scale indicates 175 A.
5. Observe voltage reading on Black (3 Volt) Voltmeter:

*If below 0.5 volts, proceed to the "Ground Circuit Resistance Test".
*If above 0.5 volts, repeat this test with voltmeter connected across each connection and each wire of the insulated circuit to
isolate the point of high resistance.
iii) Ground Circuit Resistance Test:
1. Connect test leads as shown.
2. Start the engine and adjust speed to 2000 RPM.
3. Adjust LOAD INCREASE knob until Red Ammeter Scale indicates 175 A.
4. Observe Black (3 volt) Voltmeter Scale. Test with voltmeter leads connected across each connection and each wire of the ground
circuit to isolate the point of high resistance.
A. Test Procedure Using A DVOM & Ammeter

NOTE:
A partially discharged battery works best for this test. A partially discharged battery allows most of the electrical load to be put on the
Generator (thus taking the battery out of the equation).
B. Test Procedure Using A VAT-40 or Equivalent Tester
1. Connect the Green Clamp-on Amps Pickup around the battery ground cable. Connect the NEGATIVE LOAD LEAD to the ground (-)
terminal of the battery. Connect the POSITIVE LOAD LEAD to the positive (+) terminal of the battery.
2. Set the TEST SELECTOR to the # 2 CHARGING position.
3. Turn the ignition switch to the ON position and read the rate of discharge on the Blue Ammeter Scale.
4. Start the engine and adjust the speed to 2500 RPM.
5. Adjust the LOAD INCREASE control slowly as required to obtain the highest reading on the Blue Ammeter scale. Do not allow the
voltage to drop below 12 volts.
NOTE:
For charging Systems rated above 100A, use the # 1 STARTING position and read the Red 0-500A scale.
6. Rotate LOAD INCREASE control to OFF and shut off the engine.
7. Add the ammeter readings from step 3 and 5 for the total generator output. Compare this number to the normal generator output rating
found on the housing of the generator.
NOTE:
If the output from the generator is within 10% of the specifications (amperage), the generator passes this test. If not, replace the generator.
B. Test Procedure Using the VAT-40 or Equivalent Tester

i) Voltage Regulator Test:
1. Connect the tester leads as shown in the figure.

2. Set TEST SELECTOR knob to # 3 REGULATOR position.
3. Set VOLT SELECTOR knob to INT 18 V position.
4. Operate the engine at a speed of 2000 RPM.
5. Note the reading on the voltmeter after it ceases to rise; generally the charging rate is between 5 and 10 amperes. The length of
time required depends upon the battery state of charge.
GOOD Regulator:
Voltage reading is within 14 volts.
BAD Regulator:
Voltage is above or below specified voltage range (refer to the A. Using a DVOM & Ammeter table of this TSB). Replace the
generator per Hyundai's instructions and then retest system.
ii) Diode Stator Test:
NOTE:
Continue to operate the engine at a speed of 2000 RPM.
1. With TEST SELECTOR set in the # 3 REGULATOR position, adjust the LOAD INCREASE control if necessary to obtain a
charge rate of at least 15 amperes.
2. Set the TEST SELECTOR to the # 4 DIODE STATOR position; observe the Red and Blue DIODE STATOR scale.
GOOD Regulator:
Meter reads in Blue area of DIODE STATOR scale.
BAD Regulator:
Meter reads in Red area of DIODE STATOR scale. Replace the generator per Hyundai's instructions and then retest system.
3. Return the LOAD INCREASE control to OFF and the engine speed to idle.
Electrical - Wiring Harness Testing/Repair

Number: 03-90-016
Date: JUNE, 2003
Model: ALL
Subject
WIRE HARNESS REPAIR KIT
DESCRIPTION:
As part of an essential tool shipment, all Hyundai Motor America dealers have been shipped the Wire Harness Repair Kit (Kent-Moore part #
J-46436) available through Kent-Moore. This Kit allows for the repair of electrical harnesses and connectors.
THIS BULLETIN CONTAINS:

^ Instructions for the testing and repair of wire harnesses.
^ Order information and current pricing for component refills.
^ Information for warranty claim submittal.
APPLICATION
For more details (on all models), see section 4, Page 27-29 of the "User Guide & Parts Information booklet".
The part numbers used to submit warranty claims are NOT the same as the part numbers used to reorder terminal repair components. Use the part
number of the wire harness that is being repaired as the "causal part" on the claim.
NOTE:
Use TT time for the labor operation and time.
RE-ORDER INFORMATION
All orders are to be directed to Kent-Moore at 1-800-345-2233, using the part numbers listed in this bulletin (see Shown) and in the "User Guide
and Parts Information." The re-order quantity will be the same as the original quantity. (Except for TRK00S shrink tube set). The re-order amounts
for this set will be 25.
NOTE:
You will not be able to re-order TRK011-1 through TRK011-12 in individual pieces. TRK011 will be shipped as a set.
Address:
Warren West
28635 Mound Rd.
Warren, MI 48092
Phone 1-800-345-2233
Fax 1-800-578-7375
NOTE:
DO NOT contact HMA or HMA PDC's for any related terminal/component orders.
Instructions
The Wire Harness Repair Kit has been developed to improve customer satisfaction by simplifying the repair of electrical wiring harnesses. This kit
can also save costs and improve dealer service capabilities by making repairs possible rather than the replacement of entire wire harness assemblies.
The Wire Harness Repair Kit contains the components necessary to properly test and repair a wire harness. Use the components according to the
instructions in the user guide and parts information booklet included with the kit and as explained below.
The Terminal Tension Gauge is used for measuring the tension of a female terminal.
1. Select the male shaft that matches the female terminal being checked.
2. Select the weight attachment, part number TRK003-6, following these guidelines:
a. TRK003-1, TRK003-2, use both weight attachments.
b. TRK003-3, use one weight attachment.
C. TRK004-4, TRK003-5, do not use any weight attachments.
3. Insert shaft into female terminal.
4. Hold the terminal vertically with the tension gauge hanging from the bottom.
5. If the tension of the female terminal is satisfactory, the tension gauge will not fall out of the female terminal, and there is no need to replace
the terminal.
6. If the tension of the female terminal is unsatisfactory, the tension gauge will fall out of the female terminal, if this occurs, remove and replace
with a terminal and wire assembly, including a seal when appropriate.
To use the Flat Remover Tool:
Single Locking
1. Select remover tool that best fits the wire terminal to be removed.
2. Insert remover tool into the gap between the plastic release tab and the terminal.
3. Pull gently on wire until terminal pulls free from the connector.
Double Locking
1. Use the largest remover tool (or small flat tip screwdriver) to lift up on the terminal secondary lock.
2. Select the remover tool that best fits the wire terminal to be removed.
3. Insert remover tool into the gap between the plastic release tab and the terminal.
4. Pull gently on wire until terminal pulls free from the connector.
NOTE:
If necessary, clean the inside of the connector with electrical contact cleaner first. After removing the terminal, check for any damage. If
there is any damage replace it with a new terminal.
Fuel System - Fuel Mileage Calculation

Number: 05-20-005
Model: ALL MODELS
Subject
FUEL MILEAGE CALCULATION
DESCRIPTION:
The following information and procedure is provided to assist in documenting and verifying fuel consumption.
Fuel economy is influenced by many factors. EPA ratings are estimates of the miles per gallon (MPG) possible in city and highway conditions.
Factors affecting fuel economy include:
1. Driving characteristics and conditions:
a. Quick acceleration and heavy braking
b. Excessive idling
c. Driving at higher speeds
d. Cold weather
e. Frequent stops
f. Cargo or cargo racks
g. Towing or excessive weight
h. Electrical accessories
i. Hilly terrain
2. Mileage and condition of engine
3. Condition and maintenance of vehicle
4. Fuel types and fuel quality
5. Differences between vehicles
PROCEDURE:
Use the procedure to calculate a vehicle's fuel mileage.Technical Service Bulletin # 98-80-007 Date: 980601
Wood Interior Trim Kit - Installation Procedure

Group: TRIM
Number: 98-80-007
Date: Model
1997-98 ATM SONATA
Subject
1997-98 ATM SONATA WOOD INTERIOR

TRIM INSTALLATION PROCEDURES
PARTS INFORMATION:
Use Labor Operation "00251RTT" for 0.1 hours for replacement of any individual Wood Interior Trim piece. Normal Warranty Nature and Cause
Codes apply.
Description
This TSB describes the installation procedures of the Wood interior Trim Kit 1997-98 automatic transaxle equipped Sonatas (P/N 00251-B7100).
Step 1 - Assemble All Installation Materials

^ 3M Prep-Solvent 70 (wax, grease and silicone remover) or equivalent.
^ Isopropyl alcohol (70%).
^ Scott shop towels on a roll (3) or equivalent.
^ Heat gun, hair dryer or the vehicles own heating system.
^ Lint-free, scratch resistant cloth.
^ Plastic putty knife/pry tool.
^ 3M # 06396 Adhesion Promoter or Hyundai Promoter Pen (00251-B6112).

Step 2 - Installation Precautions
^ Use protective covers on seats.
^ Do not use shop rags.
^ Do not spray cleaning solutions directly onto factory surfaces.
^ Wood trim and factory surfaces must be at 70°F (21°C) or more.
^ Do not touch exposed adhesive tape before installation. Test for interior protectants such as Armor-All with masking tape.
Step 3 - Installation Procedures When Temp. Is Below 70 Deg
^ Use heat gun, hair dryer or vehicle's own heating system to pre-heat factory instrument panel surfaces and wood trim prior to installation.
^ Hold tip of the heat source 6 inches from wood and factory surfaces. Apply heat to wood trim parts and factory surfaces one at a time. Install
part.
Step 4 - Cleaning and Preparation

^ Apply 3M Prep-Solvent 70 to a clean towel and clean all factory surfaces where wood will be installed. Wipe dry before the surfaces air dry
naturally. Re-wet towel if needed.
^ Apply isopropyl alcohol to a clean towel and clean all factory surfaces where wood will be installed. Re-wet towel if needed. Let air dry.
^ Apply 3M Adhesion Promoter in 1 thin coat to factory surfaces where wood will be installed. Let air dry for 3 minutes. (Recommend use of
Promoter Pen (P/N: 00251-B6112) to ensure that each installation receives a quality adhesion application.)
Step 5 - Installation of the Main Dash
^ Lower the steering wheel for better access.
^ Remove the tape backing from the left edge to the point on the right side of the left vent.
^ Align the left vent and the wheel control.
^ Remove the tape backing from the right edge to the point just left of the right vents.
^ Align the wheel control and both right vents.
^ Remove remaining tape backing on the horizontal leg and align to component.
^ Press entire wood trim firmly into place.
Step 6 - Install Upper Center Console
^ Apply extra heat to the lower third of the upper center console as it must bend to fit into a contour.
^ Remove the tape backing with the pull tab to the point just below the cupholder.
^ Align the top A/C control cut-out first.
^ Align the clock & radio cut-outs.
^ Hold the lower horizontal leg out and remove the remaining tape backing.
^ Press wood into the contour.
^ Align lower leg and press into place.

Step 7 - Installation of the ATM Lower Shift Console
^ Set the parking brake, turn the ignition key to the "ON" position and move the shifter lever to "2nd".
^ Remove the black plastic trim shroud from the shift console by using a plastic trim removal tool. Carefully pry up at the front. When the front is
loose, carefully slide the trim piece forward to release the horizontal tabs at the rear.
CAUTION:
The rear horizontal tabs will break if the plastic trim is pulled up.
^ Remove the tape backing with the pull tab.
^ Install black plastic trim shroud onto the wood trim, making sure to slide the rear tabs behind the woodgrain piece.
^ Hold the front edge away from the console.
^ Work from the back to front. Press the shroud front locking tabs into position.
^ Press the wood trim into the contour.
^ Apply extra heat to the front third of the wood trim to help it conform to the contour.
Step 8 - Installation of the Cupholder Door
^ Remove tape backing with the pull tab.
^ Center the wood trim onto the cupholder door.
Press into place.
Step 9 - Installation of the Ashtray Door
^ Apply extra heal to the wood grain as it must contour to fit the ashtray door.
^ Close the ashtray door.

^ Remove tape backing with pull tab.
^ Align top corners and cut-out.
^ Press wood into door contour.
Step 10 - Installation of the Lower L/H Dash
^ Align the switch cut-outs, the center leg between the switches, and the outside perimeter edges.
^ Press into place.
Step 11 - Installation of the Passenger Side Vent
^ Align cut-out for vent and control wheel.
^ Work from the top down and press into place.
Step 12 - After Installation Checklist

^ Make sure all parts are pressed fully into place.
^ Make sure all vents function properly without interfering with the wood trim (up/down).
^ Make sure that the vent open/close control functions properly without interfering with the wood trim.
^ Make sure that the cupholder functions properly (open/close) without interfering with the wood trim.
^ Make sure that the ashtray functions properly without interference.
^ Make sure that the shifter surround piece is fully snapped back into position.
^ Clean all fingerprints from the wood trim and surrounding trim.
^ If there are any problems with any of the above checks, replace the woodgrain piece, if necessary, to correct the condition.
Body - Circular Marks on Interior Glass Surfaces

Group: TRIM
Number: 04-80-002
Date: OCTOBER 2004
Model: ALL
Subject
GROUND MARKS ON THE INSIDE GLASS SURFACES
DESCRIPTION:
On some vehicles, circular marks may be visible on the inside surface of the glass. Typically these circles may only be visible when the glass is
fogged or dirty. These circular marks result from the suction cups used to handle the glass as it is assembled to the vehicle.
These marks may be removed by cleaning the glass with a good quality glass cleaner, such as Hyundai Glass Cleaner (P/N 00232-12160). Scrub the
glass two or three times with a clean cloth or paper towel, until the circle cannot be felt anymore. If this is not successful, the following procedure
can be used to clean the glass.
PRODUCTS REQUIRED:
^ Hyundai Brand Glass Cleaner (P/N 00232-12160) or equivalent
^ No Touch brand "Auto Glass Stripper" available from Napa, Shucks, Kragen etc.
^ Clean towels or lint free disposable towels
^ A damp sponge or towel
PROCEDURE:
NOTE:
Protect the trim under the glass. Any cleaners that drip onto the trim should be wiped up immediately with a clean damp cloth.
1. Fog the inside of the glass with a fine mist of glass cleaner. If the circles are present, they should be visible. Dry the glass.
2. Apply a small dab of "No Touch" brand "Auto Glass Stripper" to a clean damp towel or sponge (about a dime sized spot) and apply to the
affected area. Only work a small area at one time. Rub the product into the glass, scrubbing the surface of the glass. Do not allow the product
to drip onto the interior trim. After finishing with the first area, apply another small dab to the towel/sponge and repeat for any additional
areas.
3. Use a clean damp towel to remove the product from the glass. It may be necessary to use a few clean towels.
4. Fog the inside of the glass with a fine mist of glass cleaner. If any of the circle marks are still visible, repeat the procedure. If not, clean the
glass a final time to ensure no streaks are present.Technical Service Bulletin # 01-00-001 Date: 010301
Keys - Information For Key Cutting

Group: GENERAL
Number: 01-00-001
Date: MARCH, 2001
Model: ALL
Subject:
KEY CUTTING INFORMATION
DESCRIPTION:
This bulletin provides key cutting information for all Hyundai vehicles using Curtis Industries key cutting equipment. You may either order the
factory keys from Hyundai, through your facing PDC, or order stamped keys from Curtis Industries.
Additional information for Curtis Industries key cutting equipment can be found at their website: www.curtisindustries.com or by calling
1-800-555-2878.
Audio System - Connector Replacement

Number: 99-90-010
Model: ALL 1995 MODELS TO PRESENT
Subject: AUDIO SYSTEM CONNECTOR REPLACEMENT
DESCRIPTION:
An audio system connector replacement jumper wire is available in the event the original connector is damaged or stolen. The Electrical
Troubleshooting Manual (ETM) may be helpful when attaching the new connector onto the wire harness. Refer to the appropriate ETM for the
correct wire connections.
SERVICE PROCEDURE:
Connect the large ground wire directly to ground with a soldered ground lug. Then connect the other wires using "Solder and Shrink Wrap" or "Self
Stripping Electrical Pigtail Connectors" [3-M # 557 (3-M P/N 054007-21494) or equivalent].
CONNECTOR VIEW
CONNECTOR TERMINAL FUNCTION CHART
APPLICATION
Audio System - Diagnostic Tips

Group:
ELECTRICAL
Number:
02-90-005
Date:
JUNE, 2002
Model:
ALL
Subject:
AUDIO SYSTEM DIAGNOSTIC TIPS
DESCRIPTION:
This bulletin provides a basic guide to assist in diagnosing Hyundai audio Systems. Detailed operational information regarding each specific model
of radio is described in the vehicle's owner's manual. Additional information is available in Hyundai Shop Manuals in the "Audio" portion of the
Body Electrical section, as well as the "Sound" or "Audio" System portion of the Electrical Troubleshooting Manual.
NOTE:
Before diagnosing a customer's audio system, be sure you are familiar with the operation and features of the various Hyundai audio systems. At
times, the operation of Hyundai audio systems may be different from what the customer has assumed.
RADIO DIAGNOSTIC HINTS:
^ Verify the customer's comments and make sure the customer understands the operation of the radio.
^ Compare operation of the radio in the customer's vehicle with an identical radio in a vehicle where the radio is known to operate properly.
^ Test the radio outdoors with the hood of the vehicle closed (not under fluorescent lights).
^ Check the radio and antenna grounding.
^ Ensure that the antenna cable is fully inserted into the radio and antenna connectors. Check the antenna to ensure it is securely attached to the
vehicle and completely screwed into the base.
^ Check that the radio connector at the back of the radio case is fully inserted. Visually inspect all connector pins and receptacles.
^ Make sure the speaker connectors are properly connected to the speakers.
^ Replacing the radio should only be done thorough diagnosis shown.
RADIO DIAGNOSTIC PROCEDURES
AUDIO SYSTEM RECEPTION:
A customer may comment about a characteristic of FM reception that is really not a problem, but the normal operation of FM radios.
^ Before testing a customer's radio for reception, find three strong local stations for comparison to the customer's selected station.
^ The range of FM is less than that of AM. If the car is moving away from the station's transmitter, the signal will tend to fade out.
^ Most aftermarket window tint films will interfere with the reception on vehicles with in-glass antennas. The factory tint does not affect
reception.
CASSETTE PLAYER DIAGNOSTIC HINTS:
Verify the customer's comments and make sure the customer understands the operation of the cassette player.
^ Check inside the tape slot for foreign objects (old cassette labels, keys, coins, etc.).
^ Test the unit using a known good, pre-recorded tape.
^ Verify that any customer recorded tapes are made with good quality blank tapes. The use of 90 minutes or longer blank tapes is not
recommended.
^ Inform customers that they must keep the cassette units clean. Commercial head cleaners are available at reasonable prices for head and capstan
cleaning.
^ Replacing the radio unit should only be done following thorough diagnosis.
CASSETTE PLAYER DIAGNOSTIC PROCEDURES
COMPACT DISC PLAYER DIAGNOSTIC HINTS
^ Verify the customer's comments and make sure the customer understands the operation of the CD player
^ Test the unit using a known good compact disc.
^ Replacing the unit should only be done following thorough diagnosis.

COMPACT DISC PLAYER DIAGNOSTIC PROCEDURES
If a CD player malfunction occurs, an error code will appear on the LED display. The following list describes each error code and a diagnostic step
to assist in correcting the malfunction.
AUDIO FAULT CODES
NOTE:
Some customer recorded CDs (CDR, CDRW) may not play properly on some Hyundai radios. Paper labels should never be used in Hyundai
radios. The heat in the radios can cause the labels to separate from the CD, causing the CD mechanism to lock up. Radio replacements where
there is CD label residue in the CD player are not warrantable.
Normal warranty procedures apply (see the Labor Time Standard LTS).
The warranty covers defects in workmanship or materials. Foreign objects or labels trapped inside the tape or CD players are not covered under
warranty.
Body - Cosmoline Residue Removal

Group: PAINT
Number: 97-99-003
Date: OCTOBER, 1997
Model: ALL
Subject
COSMOLINE RESIDUE REMOVAL PROCEDURE
DESCRIPTION:
Cosmoline is a coating that is applied to vehicles to protect paint surfaces during marine transit and storage. Some vehicles may have small amounts
of cosmoline residue after the cosmoline removal and cleaning operation has been completed at the port.
The cosmoline residue may be in one of two forms: patches or a thin film. Both types of cosmoline can be removed using cleaning solvents.
Cosmoline provides protection against a variety of harmful elements and, therefore, is resistant to some cleaning agents.
HMA has identified a non-petroleum solvent that removes cosmoline residue. The product Solsafe 245 is manufactured by BIO-T and is distributed
by Mamco International Corp. Solsafe 245 can be ordered from:
Mamco International Corp. Telephone: (800) 442-4686

1042 Country Club Dr. Fax: (510) 376-7922
P.O. Box 5
Moraga, CA 94556
Cleaning Directions for Solsafe 245:

Apply Solsafe 245 directly to the cosmoline and use a clean cotton rag to wipe the surface clean, or use a cotton rag dampened with Solsafe 245 to
wipe off the cosmoline. The cotton absorbent towels are essential to the cleaning process as the towels soak up the cleaner and cosmoline mixture.
It should be noted that Solsafe 245 evaporates fairly quickly so it is not effective when it is allowed to sit or soak into the cosmoline. For thick or
difficult patches, re-apply additional Solsafe 245 and repeat the cleaning procedure until the cosmoline is removed.
Solsafe 245 will remove the cosmoline but may leave an oily residue. This residue can be cleaned with regular cleaners such as mineral spirits or
the equivalent.
Paint - Protection Film MSDS Sheet

Group: GENERAL
Number: 97-00-005
Model: ALL
Subject
PAINT PROTECTION FILM MATERIAL SAFETY DATA SHEET
DESCRIPTION:
Hyundai Motor America is now shipping vehicles to dealerships covered with a white plastic Paint Protection Film (PPF).
Included for your use and files are the required Material Safety Data Sheets (MSDS) which were supplied by the manufacturer of this product.
Please keep this information on file so copies of the attached pages can be made for distribution to your waste disposal service if requested.
We will be providing additional details pertaining to the use and handling of this product in future service bulletins.
QUALITY ASSURANCE
Document # UT 97-112
Produce Name : BR-300
Above product is guaranteed to maintain quality for up to 6 months of exposure to normal outdoors condition
1997. 11. 11.
Union Tech
Won, Dae Hee
MSDS (Material Safety Data Sheet)
1. Chemical & Manufacturer Information:

2. Composition / Information on Ingredients:
3. Hazard Identification:
4. First Aid Measures:
5. Fire Fighting Measure:
6. Handling & Storage:

7. Physical / Chemical Properties
Black Exterior Trim Parts - Refinish Procedures

Group: PAINT
Number: 98-99-003
Date: AUGUST, 1998
Model: ALL
Subject
BLACK EXTERIOR TRIM PARTS
REFINISH PROCEDURES
DESCRIPTION:
Sunlight and corrosive cleaners may discolor certain black exterior trim parts. HMA recommends the use of Exterior Trim Restore (ETR) by
ValuGard, which returns these parts to a new-like finish.
This TSB describes ValuGard ETR application procedures and provides warranty operation codes for its use.
PARTS INFORMATION
To obtain the ValuGard ETR kit, contact:
Automotive International Inc.

11308 Tamarco Drive
Cincinnati, Ohio 45242
Phone: 800-543-7156
Fax: 513-489-1329
Service Procedures
This product is not a "Dressing" and the use of ValuGard ETR must be performed per the following instructions to obtain the proper results.
WARNING:
For hand protection, wear the surgical gloves similar to the pair provided with the ValuGard kit. Follow all safety precautions listed on product
containers and the material safety data sheets.
NOTE:
DO NOT apply to hot parts or while car is in direct sunlight. This may cause the product to dry too quickly and unevenly.
1. Using soft, clean, lint free towels, clean the discolored parts with ValuGard New Car Prep to remove all waxes, silicones, grease and other
contaminants.
2. Wipe the part dry with a soft, clean lint free towel. Make sure the part being refinished is completely dry before proceeding to the next step.
3. Shake the bottle of ValuGard Color Gard well.
4. Apply a small amount of ValuGard Color Gard (3 to 4 drops) to the gray sponge supplied with the kit.
5. Using the gray sponge, apply an even coat of black ValuGard Color Gard to the part. Work the color into the part in one direction and then
repeat the process in a crosswise direction to even out the color. If necessary, go over the part, moving the sponge along a third direction.
Move the sponge evenly; moving it too fast will cause air bubbles to form. Minimize the bubbles, but do not attempt to remove tall bubbles
from the treated part. Allow 5-10 minutes to dry.
6. Inspect the part for complete and even coverage. If necessary, apply a second coat of ValuGard Color Gard (repeat steps 3-5). Be sure the
bottle of ValuGard Color Gard is well shaken!
NOTE:
Color Gard that is accidentally applied to paint surfaces on the vehicle may be easily removed with the New Car Prep Product.
7. Following the 5 to 10 minute drying time for the ValuGard Color Gard, shake the bottle of white ValuGard U.V. Gard well.
8. Apply a small amount of ValuGard U.V. Gard (3 to 4 drops) to the white sponge included with the kit.
9. Using the white sponge, apply an even coat of white ValuGard U.V. Gard to the part. Allow a 5 to 10 minute drying time. Before the paint
fully dries, be sure that there are no bubbles. If any bubbles are present, work them into the part.
10. Inspect the part for complete and even coverage. If necessary, apply a second light coat of ValuGard U.V. Gard to even out the surface
(repeat steps 7-9).
NOTE:
DO NOT expose treated part to any water or water based cleaner for 24 hours.
NOTE:
DO NOT throw away used sponges. They may be reused. Rinse out sponges following use, with water. Make sure the sponges are completely
dry before they are reused. Application of the ValuGard product to the sponges softens and reactivates the sponges, allowing for multiple use.
NOTE:
Store all unused products and dispose of used material according to Federal, State and Local requirements.
Brake Fluid - Specifications

Group
CHASSIS
Number
00-50-003
Date
SEPTEMBER, 2000
Model
ALL
Subject
BRAKE FLUID SPECIFICATIONS
DESCRIPTION:
The table shows brake fluid specifications by model application.
Effective with "New Models" (*) production, the material of the rubber parts used in the brake system has been changed to provide compatibility
with "DOT 4" fluid. Therefore, both DOT 3 and DOT 4 specifications brake fluid can be used in "New Models"; however, only DOT 3
specification brake fluid is may be used in "Previous Models" (**)
NOTE:
This information is contained in the applicable shop manuals.
Remark: Any models not shown as "New Models"----->use DOT 3 brake fluid
A/T - Reman, Filler Tube/Dipstick Installation

Number: 00-40-001
Group: AUTOMATIC TRANSAXLE
Date: JANUARY, 2000
Subject: AUTOMATIC TRANSAXLE OIL FILLER TUBE AND OIL LEVEL GAUGE
Model: ALL
DESCRIPTION:
In early 2OOO, Hyundai's automatic transaxle remanufacturer will no longer install an oil filler tube and oil level gauge (dipstick) on
remanufactured automatic transaxles, and will install a plug in place of the oil filler tube. The remanufacturer will place an O-ring for the oil filler
tube inside an envelope and attach the envelope to the manual control lever.
SERVICE PROCEDURE:
1. Remove the dipstick and oil filler tube from the removed transaxle.
2. Open the large plastic envelope and remove the O-ring from the package.
3. Clean the oil filler tube and install the O-ring on the oil filler tube.
4. Reinstall the oil filler tube and dipstick on the new transaxle.
PARTS INFORMATION:
Model Part Part Number

All O-Ring 42115-37000 Technical Service Bulletin # 03-97-001 Date: 030601
A/C - Thermistor Relocation/Part Change

Group
97 - CLIMATE CONTROL
Number
03-97-001
Date
06-2003
Model
Santa Fe 2001 - 2003, Sonata 1989 - 2003, XG 300 2001 and KG 350 2002 - 2003
Subject
THERMISTOR COMPONENT AND LOCATION CHANGE
DESCRIPTION:
A new thermistor is available for Santa Fe, Sonata and XG. See table for part number and system application (manually controlled or full automatic
temperature control system).
The location of the thermistor has also been changed. The new location is in the upper corner, toward the rear of the vehicle.
The new location and new part increase the thermal sensitivity of the system to prevent freezing of the evaporator core. The thermistor MUST be
installed in the fins of the evaporator, and on the air outlet (cold air) side of the evaporator.
Technical Service Bulletin # 05-40-007-1 Date: 050701
M/T - Gear Lubricant Applications/Interchangeability

Group: TRANSAXLE
Number: 05-40-007-1
Date: JULY, 2005
Model: ALL
Subject
MANUAL TRANSAXLE GEAR LUBRICANT
This TSB supersedes TSB # 05-40-007 to update part number information.
DESCRIPTION:
A new 75W/85 manual transaxle gear lubricant has been adopted in production. The purpose of this bulletin is to provide the following
information:
^ Vehicle model, transaxle type and production release date information
^ Previous and new gear lubricant part number information
^ Gear lubricant interchangeability information

The TABLE provides the application information for the new 75W/85, gear lubricant.
PARTS INFORMATION:
Brake System - Noise Explanation/Diagnosis

Group: CHASSIS
Number: 98-50-001
Date: JANUARY, 1998
Model: ALL
Subject
DISC BRAKE NOISE INFORMATION
DESCRIPTION:
Vehicles may exhibit brake noise under certain driving conditions. This bulletin provides information regarding some brake noises and appropriate
service procedures for each condition. This information may be useful when explaining brake noises to your customers.
Note:
This TSB does not replace any previous bulletin.
General Brake/Tip Information

Brake systems must provide optimum braking performance under various driving conditions. One of the most important components in the brake
system is the brake pad material. The following are affected by brake pad material characteristics:
- Stopping distance
- Operating temperatures
- Brake pedal effort
- Brake pad and rotor wear
- Moisture resistance
- Friction coefficient stability
- Operating noise
Higher brake operating noise levels may occur as a result of optimizing factors that ensure brake operational performance.
Brake noises such as squealing, squeaking and grinding may result in questions by customers, but some of these noises are normal. Almost all disc
brake noises are caused by vibration of pads and calipers as the pads slide against the rotors to stop the vehicle. The following "Tips" may be
helpful in resolving brake noise conditions:
- Always listen to the customer's comments thoroughly.
- Do not attempt to repair a brake noise condition without verifying it first.
- Rear brake noise may sometimes be mistaken for front brake noise,
- If possible, verify the brake noise condition both with and without the driver side window down.
- Always check for the latest available information on the condition (Technical Service Bulletins (TSBs), Tech Net Times, etc.).
Service Information
If no service information is available for repair of brake noise, follow the procedures:
1. Replace brake pads with the latest available part number.
- Chamfer (smooth out) edges of pad by about 2 mm before installing.
- Apply anti squeal high viscosity brake disc quieter on pads as directed by the product manufacturer.
2. Check rotors for wear and/or corrosion.
- If the rotors pass visual inspection, machine the rotors, applying a non directional swirl finish.
- Repair or replace rotors as necessary (see appropriate Shop Manual for rotor specification and service procedure).
Note:
Whenever possible, an on car lathe is recommended for machining rotors.
3. Apply Squeak Relief Spray on Brake Treatment on rotors as directed by the product manufacturer (available at most auto parts stores).
4. Perform "bedding in" procedure, as noted, to reduce brake noise and to make pads last longer.
A. From 30 to 40 mph, brake gently until the vehicle almost stops.
B. Resume normal speed for 30 to 40 seconds to cool the brakes.
C. Repeat steps A & B five times.
D. Accelerate vehicle to 55 mph and brake gently down to 20 mph.

E. Resume normal speed for 30 to 40 seconds to cool the brakes.
F. Repeat steps D & E five times to complete the "bedding in" procedure for reducing brake noise.
Brake Noises That Do Not Indicate Malfunction

1. Groaning/Creeping noise at low mileage (0-300 miles):
- Noise occurs with light to medium pedal force.
- Noise occurs during medium speed stops (20-40 mph).
- Noise usually doesn't occur on the first or second stop.
- Noise occurs with warm or hot brakes (not cold).
- There may be a low frequency "judder" vibration associated with the noise.
Hyundai applies protective coatings to the brake rotors and pads to reduce corrosion during shipping and storage. These coatings may cause the
groaning noise until they are worn off. Under normal driving conditions, this may take about 300 miles. If this noise occurs even after the first 300
miles, it is not necessary to attempt any repairs.
Service procedure:
None
2. Squeaking/Squealing Noise:
- Noise occurs with light to medium pedal force.
- Noise occurs during low speed stops (5-20 mph).
- Noise is more noticeable during warm, dry weather.
This noise is common on vehicles with high performance potential that are able to stop in short distances from high speeds.
Service procedure:
Follow "Service Information" section of this TSB.
3. High pitched squeaking/scraping noise:
- Noise occurs whenever brakes are applied.
- Noise may occur from just one wheel.
Hyundai uses pad wear indicators to provide an audible warning when the brake pads need replacement. Spring steel tabs that are attached to the
brake pad scrape lightly on the rotor surface when the pad is worn down to the point where it should be replaced. The pad wear indicator doesn't
damage the rotor surface if the pads are replaced in a reasonable time.
Service procedure:
Replace brake pads with latest available pads. Check the rotor surface for damage and machine or replace rotor as necessary.
Rear Disc Brake - Minimum Thickness (Manual Addition)

Group: CHASSIS
Number: 99-50-003
Date: APRIL, 1999
Model 1996-99 ELANTRA

1997-99 TIBURON
1995-98 SONATA, 1999 SONATA
Subject
REAR DISC BRAKE MINIMUM THICKNESS
(SHOP MANUAL ADDITION)
NOTE:
This TSB supersedes TSB # 98-50-002 to include updated 1999 information
DESCRIPTION:
Some Shop Manuals do not provide the rear brake disc service limit (minimum thickness) value. The table provides the specifications and service
limit values for rear brake disc thickness.
NOTE:
Inspect the brake disc thickness using a micrometer. If the disc thickness is below the "service limit", replace the brake disc.
The service limit value is stamped on the disc flange.
A/C - Cabin Air Filter Application Chart

Group
97 - CLIMATE CONTROL
Number
03-97-003
Date
11-2003
Model
Accent 1995-2004, Elantra 1992-2004, Excel 1986-1994, Santa Fe 2001-2004, Scoupe 1991-1995, Sonata 1989-2004, Tiburon 1997-2004, XG 300
2001 AND XG 350 2002-2004
Subject
CABIN AIR FILTER APPLICATION CHART
DESCRIPTION:
The following tables provide factory installed cabin air filter applications, and also note which vehicles may be equipped with cabin air filters if
they were not installed during production.
A cabin air filter is a replaceable paper element filter that removes particulates such as dust from the air.
The filter locations for these vehicles vary; however, all are accessed by removing or lowering the glove box and/or glove box housing.
The typical service interval is 12,000 miles or 1 year, whichever occurs first. More frequent maintenance may be required in very dusty
environments which may clog the filter. Particulate debris becomes trapped in the replaceable filter and is removed from the system during routine
maintenance. Odor from debris in the filter may also be remedied by replacing the air filter.
NOTE
Replacement of the cabin air filter is considered a maintenance item and not covered under warranty.
The table shows which vehicles were equipped with a cabin air filter during production and which vehicles may be equipped with filters after
production if desired.
NOTE
Corrections to TSB 03-97-002:
1. TSB does NOT indicate that the Santa Fe also changed to the two (2) piece cabin air filter on March 29, 2003 (with the XG and Sonata).
2. TSB incorrectly indicates two (2) pieces of part number 97619-3D000. The correct quantity is one (1) piece for XG, Sonata, and Santa Fe
built after March 29, 2003.
NOTE
1. The replacement procedures outlined in TSB 03-97-002 are still applicable for the XG, Sonata and Santa Fe.
2. The installation procedures for the Accent, Elantra, Tiburon and XG 350 can be found in the 2004 Owners Manuals in the "Do It
Yourself Maintenance" section. Separate TSBs will be published for earlier models. Access to the air filter in all cases is behind the glove
box and glove box housing.
3. The arrow on the cabin air filter must always point in the direction of air flow.
Towing - M/T Requirements
Group:
GENERAL
Number:
00-00-002
Date:
AUGUST, 2000
Model:
ALL FRONT WHEEL DRIVE
Subject:
TOWING REQUIREMENTS
DESCRIPTION:
This bulletin provides requirements for towing Hyundai vehicles equipped with manual transaxles with all four wheels on the ground, such as may
be done to tow behind a recreational vehicle.
CAUTION:
Any Hyundai vehicle equipped with an automatic transaxle must NOT be towed with all four wheels on the ground behind another vehicle.
This may seriously damage the vehicle's transaxle.
MANUAL TRANSAXLE EQUIPPED VEHICLE REQUIREMENTS:
Any Hyundai vehicle equipped with a manual transaxle may be towed with all four wheels on the ground behind another vehicle, such as a
Recreational Vehicle (RV), as long as the following six conditions are met:
1. Transaxle oil is at the recommended level
2. Transaxle is in correct working order
3. Parking brake is released
4. Gearshift is in NEUTRAL
5. Steering wheel is UNLOCKED with the key in the ignition and in the "ACC" position
NOTE:
When you leave the key in the "ACC" position, make sure all accessories are turned off to prevent battery drain.
6. Vehicle is towed from the front with all four wheels on the ground
WARNING:
When towing has been completed, be sure to turn the key off, remove it from the ignition and set the parking brake. Do not leave the key in the
ignition with the vehicle unattended.
NOTE:
Emergency and disabled vehicle towing procedures are given in the respective model's owner's manual.
Vehicle - Towing Requirements & Precautions

Group: GENERAL
Number: 04-00-002
Date: JUNE, 2004
Model: ALL
Subject
RECREATIONAL TOWING REQUIREMENTS
DESCRIPTION:
This bulletin provides requirements for towing Hyundai vehicles equipped with manual transaxles with all four wheels on the ground, such as may
be done to tow behind a recreational vehicle.
CAUTION:
Any Hyundai vehicle equipped with an automatic transaxle, 2WD or 4WD, MUST NOT be towed with all four wheels on the ground behind
another vehicle. This may seriously damage the vehicle's transaxle.
MANUAL TRANSAXLE EQUIPPED 2WD HYUNDAI VEHICLE TOWING REQUIREMENTS:
NOTE:
Confirm that the "recreational" tow vehicle has the capacity to tow a Hyundai vehicle.
Any Hyundai vehicle equipped with a manual transaxle may be towed with all four wheels on the ground behind another vehicle, such as a
Recreational Vehicle (RV), as long as the following conditions are met:
NOTE:
WARNING:
NOTE:
Emergency and disabled vehicle towing procedures are given in detail in the respective model's owner's manual; however, the following
information quickly summarizes the various recommended towing procedures to be used by Hyundai dealers or by commercial towing
companies.Technical Service Bulletin # 05-00-001 Date: 050201
Vehicle - RV Towing Guidelines/Precautions

Group: GENERAL
Number: 05-00-001
Model: ALL
Subject
DESCRIPTION:
This bulletin provides requirements for towing 2WD Hyundai vehicles equipped with manual transaxles with all four wheels on the ground, such as
may be done to tow behind a recreational vehicle.
CAUTION:
The combinations listed in the TABLE MUST NOT be towed behind a recreational vehicle with all four wheels on the ground.
MANUAL TRANSAXLE EQUIPPED 2WD HYUNDAI VEHICLE TOWING
REQUIREMENTS:
NOTE:
Any Hyundai 2WD vehicle equipped with a manual transaxle may be towed with all four wheels on the ground behind another vehicle, such as a
6. Front tires are of the same size
7. Front tire pressures are equal and inflated to the recommended pressure
NOTE:
WARNING:
NOTE:
information quickly summarizes the various recommended towing procedures to be used by Hyundai dealers or by commercial truck towing
companies.Technical Service Bulletin # 06-36-006 Date: 061201
Emissions - EGR System Diagnosis

Number: 06-36-006
Model:
SONATA I4, XG300/350 & SANTA FE
Subject:
EXHAUST GAS RECIRCULATION (EGR) SYSTEM DIAGNOSIS
THIS BULLETIN SUPERSEDES TSB 01-36-021
TSB Outline
DESCRIPTION:
The models listed below are equipped with engines that utilize Exhaust Gas Recirculation (EGR) to reduce output of Oxides of Nitrogen (NOx).
The basic system described below has been in use on all Hyundai vehicles with external EGR Systems from the 1996 MY.
APPLICABLE MODELS:
^ 1996 to 1998 Sonata I4 and V6
^ 1999 to 2005 Sonata I4
^ 2001 - 2005 XG300/350
^ 2001 - 2004 Santa Fe I4
^ 2003 - 2006 Santa Fe 3.5L V6
HOW EGR WORKS:
When activated, the EGR Valve directs a metered amount of exhaust gas into the intake manifold and thereby into the combustion chamber.
The addition of the inert exhaust gas (does not chemically react during the combustion process) reduces peak combustion temperatures.
Lower peak combustion temperatures result in lower heat-related emissions of Nitrous-Oxides (NOx).
Some engines do not require a separate EGR System. They achieve an EGR effect by valve overlap.
This TSB concentrates on vehicles with "external EGR systems.
NOTE:
EGR is NOT activated when:
^ The engine is idling.
^ The engine speed is above 4,000 RPM.
^ The engine coolant temperature is low (less than 113°F).
^ The vehicle is not moving.
Schematic Diagram of the EGR System (XG300).
EGR SYSTEM COMPONENTS AND OVERVIEW:

(1) EGR System photographs (The XG300 system is shown for illustration purposes. The systems in the Sonata I4 and Santa Fe I4 are very
similar.)
(2) EGR System Components and their Function:

1. EGR Valve: This valve directly controls the flow of Exhaust Gases to the intake manifold. The EGR Valve is controlled by vacuum applied
to a diaphragm. When vacuum is applied, the diaphragm moves and opens a pintle valve.
2. Vacuum Control Valve: To prevent excessive vacuum in the system, this valve regulates the vacuum. When the vacuum is greater than
approximately 7 in-Hg (180 mm-Hg = 24 kPa = 3.5 psi), the Vacuum Control Valve opens to the atmosphere until the vacuum level
decreases to 7 in-Hg. Regulating vacuum in the system results in improved EGR control and drivability.
3. EGR Solenoid Valve: The EGR Valve is controlled by the EGR Solenoid Valve which is normally an "open" valve. That is, when power is
NOT applied to the EGR Solenoid Valve, the valve is open (can blow through the valve). When the EGR Solenoid Valve is energized (via a
pulse-width signal from the ECM), the valve closes and allows the vacuum from the intake manifold to be applied to the EGR Valve (thus,
activating the EGR).
4. MAP Sensor: The MAP sensor is used to detect pressure (or vacuum) changes in the intake manifold. When the EGR system is tested by
activating the EGR under specific conditions (see the diagnostic logic in the next section), the MAP sensor signal change is what's used to
determine if the EGR system is working properly.
5. Vacuum T-Connector: This part allows the vacuum to bleed off through the EGR Solenoid Valve to the Air Intake side of the throttle body.
6. Throttle Body: The vacuum source and the Bleed-off back to the Air Intake side of the throttle plate is "plumbed" through the throttle body's
"E" Port (vacuum source) and the "A" Port (bleed-offside).
7. Green Hoses: The green striped hoses signify the "vacuum" side of the system.
8. Yellow Hoses: The yellow striped hoses signify the "bleed" side of the system.
9. In-Line Orifices: There are orifices in the system (three in the case of the XG300) to limit the "flow" in the system. Limiting the flow in the
system limits the volume of air bypassing the throttle plate.
10. ECM: By processing a variety of input signals, the ECM determines when to activate EGR.
VACUUM "FLOW" DIAGRAMS:
EGR "OFF": Note that the EGR solenoid is "normally open" which allows the vacuum to "bleed off".
EGR "ON": The EGR solenoid is energized and the vacuum path back to the throttle body "A" port is cut off. Thus, the vacuum is APPLIED to the
EGR valve's diaphragm.
EGR SYSTEM DIAGNOSIS:
(1) PCM Diagnostic Trouble Code (DTC) Logic for P0401 (INSUFFICIENT EGR FLOW):
The PCM monitors the EGR system for proper function by conducting a test under the following conditions (this is also called EGR Monitoring):
^ The engine is warming up (Engine Coolant Temperature > 113°F)
^ Engine Load is < 22%
^ Engine Speed is between 968 and 1,875 RPM
^ Idle Position Switch = ON (no throttle input)
^ Battery Voltage > 10V
^ Vehicle is decelerating
If the above conditions are met, the EGR Valve is closed for 1 second then is opened for about 1 second. During this later 1 second open period, the
MAP sensor signal is monitored.
The PCM, using the Manifold Absolute Pressure (MAP) Sensor, measures the pressure change in the intake manifold during the above test. If the
pressure changes less than 26mm-Hg -- millimeters of Mercury (equivalent to 0.5 psi = 3.5 kPa = 1 in-Hg), then a problem is detected and code
P0401(INSUFFICIENT EGR FLOW) is set in the PCM.
After two consecutive trips of detecting the fault, the Check Engine Light is turned ON and the code & freeze frame data are available.
(2) Testing Procedures for P0401:
1. Visual Inspection:
^ Check that all hoses and the EGR Solenoid Connector are connected properly.
^ Check for cracks or cuts in the hoses. Gently bend the hoses to reveal any cuts that may be difficult to see.
^ Check the metal tubes and the EGR Solenoid body and tubes for any signs of cracks or damage.
2. Vacuum System Test:
a. Engine is Idling in the stall.
b. Activate the EGR Valve by pinching off the yellow striped hose.
^ When the vacuum "bleed off" path is closed, the EGR Valve should open. This will cause the engine to stumble and stall.
^ IF cutting-off the vacuum bleed-path does NOT cause the engine to run rough and stall, THEN there is a leak or blockage in the
vacuum system.
^ Check for leaks or blockages by starting at the throttle body "E" Port. Pull off the vacuum hose at the "E" Port, vacuum should be
felt at the throttle body's "E" port tube.
^ Then, check each hose and metal tube (working from the "E" port towards the EGR Solenoid Valve). Check each pathway using a
vacuum pump with a built in gauge. Create about 7 in-Hg (23 kPa = 3.3 psi = 180 mm-Hg) of vacuum in each component/hose.
This small amount of vacuum is enough to fully open the EGR Valve.
^ Check the function of the Vacuum Control Valve. Remove the green striped hose at the throttle body and attach a vacuum pump.
Plug the other port of the Vacuum Control Valve. Apply a vacuum greater than 7 in Hg (23 kPa = 3.3 psi = 180 mm Hg). The
Vacuum Control Valve should regulate the vacuum down and hold vacuum at approximately 7 in Hg. If the vacuum does not hold,
the Vacuum Control Valve needs to be replaced.
^ Connect a vacuum pump/gauge to the EGR Valve. Apply 7 in Hg (23 kPa = 3.3 psi) of vacuum; the valve should open fully and the
vacuum should NOT bleed off. If the vacuum does not hold, then the EGR Valve needs to be replaced.
^ Apply 1 in Hg (3.4 kPa = 0.5 psi) of vacuum directly to the EGR Valve; the valve should not open and air should not blow past the
pintle valve.
^ The EGR Solenoid Valve may be intermittently sticking closed when not energized. To test this condition, remove the EGR
Solenoid Valve and repeatedly apply and remove 12V power to the Solenoid. Using a vacuum pump/gauge, check if the EGR
Solenoid sticks in the closed position (vacuum is held when it should not be).
^ Conversely, the EGR Solenoid Valve may not be closing properly when energized. Apply 12V to the EGR Solenoid Valve. Attach
a vacuum pump/gauge and check if the valve is closed (holds vacuum). This condition may be intermittent and may require the test
to be conducted repeatedly to reproduce the "sticking open" condition. An alternative test is to energize the EGR solenoid while the
car is idling (apply 12V directly to solenoid). If the engine does not stumble and stall, then the EGR Solenoid is not closing
properly and needs to be replaced.
^ An intermittent "leak" in the vacuum system is another possibility. This condition can be caused by a cut vacuum hose, which only
leaks when flexed as a result of engine movement.
^ Check the EGR Valve's pintle for sticking, excessive carbon deposits, etc.
3. If the code P0401 is set and the engine is idling rough:
^ Then, the EGR Valve is being held open at idle, when it should not be.
^ This condition could be caused by an EGR Solenoid Valve which is sticking closed when NOT energized by the ECM. (Remember that
this valve is "normally open.")
^ This condition could also be caused by a blockage of the "bleed path." Check the yellow striped hoses for a blockage. Also check the
EGR Solenoid Valve's built-in orifice for blockage.
(3) PCM DTC Logic for P0403 (EGR Solenoid -- Malfunction):
^ The ECM monitors the EGR electrical circuit for the presence of the proper EGR signal.
^ A typical EGR duty signal is shown below (Hi-Scan Pro Recording).
^ As can be seen, there is a voltage "surge" at the beginning of each pulse of the EGR signal. This surge voltage is monitored by the ECM.
^ If the surge voltage is less than [Vb (battery voltage) + 2V] -- typically totalling about 16 Volts --, then the electrical system is considered
to be malfunctioning and code P0403 is set in the ECM.
^ After two consecutive trips of detecting the fault, the Check Engine Light is turned ON and the code & freeze frame are available.
(4) Testing Procedure for P0403:
^ Check the integrity of the electrical system. Check that all electrical connectors (at the EGR Solenoid Valve and the ECM) are properly
connected and that all pins are in good condition.
^ Check the continuity of the wiring. Check for shorts or opens.
^ Using GDS or the Hi-Scan Pro (in the oscilloscope mode), examine the EGR signal when the EGR is activated. (see the typical signal
above). The conditions when the EGR is operating are:
^ Vehicle is moving
^ Engine is not idling
^ Idle switch is not "on" (that is, there is some throttle input)
Vehicle - Perchlorate Material Handling/Disposal

Group: GENERAL
Number: 07-00-001
Model:
ALL
Subject:
DISPOSAL/HANDLING OF PERCHLORATE CONTAINING MATERIALS - CALIFORNIA LEGAL REQUIREMENTS
DESCRIPTION:
For California Dealers Only
This bulletin clarifies dealer responsibilities under California law regarding the disposal requirements for perchlorate-containing materials of Title
22 of the California Code of Regulations Section 67384.10.
Perchlorate is a chemical that has been found to contaminate drinking water, ground water, surface water, and soil. In an effort to decrease the
amount of perchlorate released into the environment, California is regulating the disposal of materials containing per-chlorate such as airbags, seat
belt pre-tensioner initiators, TPMS valve sensors, and batteries for keyless entry systems.
Once an airbag or a seat belt pretensioner is deployed, the perchlorate is consumed in the burn process and is no longer regulated. The Department
of Toxic Substance Control has advised manufacturers that pursuant to section 67384.2(b)(6) deployed airbags and pretensioners are exempt from
the Perchlorate BMP (Best Management Practices) regulations. Thus, you can handle those items as you have handled them in the past.
In the event that you replace an undeployed airbag or pretensioner, you may use such parts during the training of dealer personnel on the
deployment procedure of those items. HMA recommends that dealers periodically demonstrate airbag and seat belt pretensioner deployment as part
of a dealer training program on how to properly deploy these components.
If airbags and seat belt pretensioners are not deployed prior to disposal, they are considered hazardous waste and you should follow the normal
procedures for the disposal of such materials in accordance with California hazardous waste regulations.
Hyundai also reminds you of a recent change in California law that waste batteries from keyless entry remote systems and TPMS valve sensors may
not be discarded in the trash. See California Universal Waste Rule, 22 CCR section 66273.13. Waste batteries must be taken to a local recycle
collection center. A center near you can be found at http://www.earth911.org. If you have any questions regarding your implementation obligations
under California law, please consult with the legal counsel you regularly consult with on waste issues.
Additional information is available from the California Department of Toxic Substances Control at http
://www.dtsc.ca.gov/Hazardouswaste/Perchlorate/index.cfm.
A/T - Automatic Transaxle Fluid Level

Group: TRANSMISSION
Number: 06-40-016
Model:
ALL
Subject:
AUTOMATIC TRANSAXLE FLUID LEVEL
This TSB supersedes TSB # 03-40-019 to add new model information
DESCRIPTION:
The automatic transaxle fluid (ATF) level must be checked during Pre-Delivery Inspection (PDI). Low ATF level may cause the following
driveability conditions:
^ Engine "flare" during the 2-3 shift (engine speed increases during the shift) at light throttle when the ATF is cold
^ Harsh or delayed shift during acceleration from a stop following a rapid deceleration
PROCEDURE:
1. Attach a Hi-Scan Pro or GDS and select "Automatic Transaxle" menu, "Current Data" menu and "Fluid Temperature".
2. Drive the vehicle until the ATF is at normal operating temperature above 75°C (167°F).
3. Park the vehicle on a level surface and set the parking brake. Start the engine and move the shift lever through each gear, then to "Neutral".
4. Check the ATF level on the dipstick. Add Hyundai SPIII until the level is within the "HOT" or "75C" range.
NOTE:
The 2008 Veracruz requires JWS 3309, Type T-IV ATF. Do not use SPIII.
NOTE:
The "COLD" range is only used for estimating ATF level. The ATF level can be accurately checked only if the ATF temperature is at
normal operating temperature above 75°C (167°F).
NOTE:
Use only Hyundai SPIII ATF, Diamond SPIII ATF or other brands meeting the SPIII specification approved by Hyundai Motor
Company.
NOTE:
SPIII has a red color when new; however, the ATF may change color to a dark red or brown after 10,000 to 25,000 miles in service. This
change is normal for this type of ATF and does not indicate an internal transaxle condition.
MAINTENANCE INTERVAL:
Refer to the maintenance schedule in the owner's manuals for maintenance requirements.

Paint - Cloudy Appearance

Group: PAINT
Number: 07-99-001
Date: JANUARY, 2007
Model:
ALL
Subject:
CLOUDED PAINT CORRECTIVE PROCEDURE
DESCRIPTION:
This TSB updates TSB 00-99-001.
Hyundai applies a Paint Protection Film (PPF) on new vehicles before delivery to dealerships. It provides a barrier between the paint and
contaminants such as rail dust, acid rain, and industrial fallout. In rare cases the paint can become clouded under the PPF. These spots are the result
of moisture trapped between the PPF and the paint.
CLOUDED PAINT SPOT REMOVAL PROCEDURE:
1. Remove all PPF from vehicle.
2. Clean the vehicle. If the spots are still visible, use an infrared light, similar to the type used in a body shop, to heat the affected area. Most
infrared lights can be set up about 2 feet from the paint surface to achieve a hot surface temperature, depending on the heat output. Do not let
the paint temperature exceed 180°F. Be careful not to allow nearby trim to overheat (above 180°F).
3. Allow the infrared light to heat the vehicle for a minimum of 15 minutes, a maximum of 3 hours. Check the vehicle every 15 minutes to
ensure it is not overly hot. You should be able to briefly touch the heated area, but it should be uncomfortably hot.
ADDITIONAL COMMENTS:
Small spots can be removed with a heat gun. Hold the heat gun about 12-18 inches from the spot, keeping it moving. Do not let the paint
temperature exceed 180°F.
Heating for 10 to 15 minutes should remove the spot. If the spot persists after 15 minutes, switch to the procedure mentioned above.
Wiping the spot with undiluted alcohol will accelerate the drying. Wipe a rag with the alcohol across the area before heating. Do not apply
cool alcohol to a heated panel, or while heat is being applied.
CAUTION 1:
Use the proper precautions when using alcohol near a heat source.
CAUTION 2:
During heating, anti corrosive wax used on the back side of the metal panels may liquefy. Some may drain out of the drain holes.
Power Steering - PSF-4 Fluid Compatibility/Part Number

Group: CHASSIS
Number: 07-50-002
Model:
ALL
Subject:
PSF-4, HYUNDAI GENUINE POWER STEERING FLUID
DESCRIPTION
This bulletin provides the PSF-4, Hyundai Genuine power Steering Fluid, part number and interchangeability information.
DESCRIPTION PART NUMBER
PSF-4 Hyundai Genuine 00232-06010

Power Steering Fluid
INTERCHANGEABILITY
^ PSF-4 to PSF-3----> Topping off or adding up to 50% PSF-4 to a PSF-. system is acceptable.
NOTE:
Do not add more then 50% of the total system volume of PSF-4 to PSF-3. The PSF-3 fluid should be drained and replaced with PSF-4 power
steering fluid.
^ PSF-3 to PSF-4----> Not OK (Do not add PSF-3 to a PSF-4 system) Technical Service Bulletin # 07-50-003 Date: 070301
Brakes - VOC Compliant Brake Cleaner

Group: CHASSIS
Number: 07-50-003
Date: MARCH, 2007
Model:
ALL
Subject:
BRAKE CLEANER - VOC COMPLIANT
DESCRIPTION:
The state of Michigan has recently prohibited the sale of brake cleaners containing high percentages of VOC (Volatile Organic Compounds). Other
states also prohibit the sale of high - VOC percentage brake cleaners. They are: California, Delaware, Washington, D.C., Maine, Maryland, New
Hampshire, New Jersey, New York, Pennsylvania, and Virginia.
Brake cleaner part number 00232-07001 is available for dealers in those states and complies with those states/VOC regulations.
A/T - Diagnostic Test Procedures

Group: TRANSAXLE
Number: 07-40-007
Date: JUNE 2007
Model:
ALL
Subject:
AUTOMATIC TRANSAXLE STALL TEST PROCEDURE
This TSB revises TSB 06-40-014 to add Veracruz information
DESCRIPTION:
To diagnose a transaxle for "slipping or Diagnostic Trouble Codes P0731, P0732, P0733, P0734, P0735 or P0736 (incorrect gear ratio), perform a
stall test using the:
^ A/T Tester II, P/N 09450-AT000 (see TSB 00-40-008) or A/T Tester Plus
^ "Stall Test Procedure without A/T Tester":
STALL TEST PROCEDURE WITHOUT A/T TESTER:
1. Check the automatic transaxle fluid level according to the following TSB. Add ATF, if necessary to bring the level within the "HOT range.
^ TSB 03-40-019 - All except Veracruz
^ TSB 07-40-004 - Veracruz only
2. Firmly apply the parking brake and place blocks in front and behind both front wheels.
CAUTION:
Do not let anybody stand in front of or behind the vehicle during the test.
3. Start the engine and move the select lever to "D".
4. Press and hold the brake pedal, then fully depress the accelerator and record the engine speed.
CAUTION:
Do not hold the throttle fully open for more than 5 seconds. Release the throttle and allow the engine to idle in "N" for 5 seconds.
5. Confirm the stall speed is within the specifications shown in the related shop manual (approximately 2000-2900 rpm at sea level, depending
on model).
6. Move the shift lever to "R", then repeat Steps 4-5. Go to Step 7.
7. Move the shift lever to the "Sports Mode" position, then move the lever forward to select "Gear 2". Repeat Steps 4-5 to test gear 2. For
Veracruz only move the lever forward to select "Gear 3". Repeat Steps 4-5 to test gear 3. Go to Step 8.
8. Disconnect the connector to the solenoid, then repeat Steps 4-5 to test gear 3 (except Veracruz).
VEHICLES EQUIPPED WITH SPORTS MODE - EXCEPT VERACRUZ: (This procedure tests the clutches and brakes) shown.
VEHICLES WITHOUT SPORTS MODE (This procedure tests the clutches and brakes shown).
VERACRUZ ONLY: (This procedure tests the clutches and brakes shown. The C2 clutch can be tested for slipping by driving in 4th, 5th and
6th gear).
Labor time for the stall test is included in 45000R00 (Replace automatic transaxle).
A/T - Cooler Flushing Procedure

Group: TRANSAXLE
Number: 07-40-011
Date: AUGUST, 2007
Model:
ALL
Subject:
AUTOMATIC TRANSAXLE OIL COOLER FLUSHING
This bulletin revises TSB 98-40-004 to update use of alternate oil cooler flushers
DESCRIPTION
Whenever an automatic transaxle is replaced or overhauled, the oil cooler must be flushed to remove contaminants such as metal particles and
clutch material. Improper flushing may result in severe damage to the replacement transaxle.
SERVICE PROCEDURE
WARNING:
^ Wear safety glasses and rubber gloves when flushing the oil cooler.
^ Use aerosol oil cooler flush only with adequate ventilation.
^ Avoid contact with eyes and skin.
^ Do not breathe vapors or spray mist.
1. Mark the hoses with tape or tags so they can be reconnected correctly. Disconnect the oil cooler inlet and outlet hoses from the oil cooler
tubes.
2. Insert the nozzle of the aerosol can to either hose and secure it with a hose clamp. Position the other hose so that it discharges into a waste
container.
3. Remove the protective cap. Hold the can upright and press firmly on the button to release the solution. Flush for 15-20 seconds until clear
liquid comes from the outlet hose.
4. Insert the aerosol flush to the other hose and flush in the other direction until clear liquid comes from the outlet hose. For best results, use the
entire contents of the aerosol can.
NOTE:
Clear liquid must flow freely in both directions through the oil cooler. If not, the oil cooler is clogged with debris and must be replaced.
5. When the flush has been expelled, turn the can upside down and blow any remaining liquid out of the cooler.
6. Reconnect the cooler hoses to the transaxle and secure with clamps.
7. Add ATF. Start the vehicle and check for leaks.
8. Check the automatic transaxle fluid (ATF) level with the engine idling in "N". Add ATF to bring the ATF level to the top of the "FULL"
mark.
NOTE:
Dispose of the waste solution in conformance with local, state and Federal regulations.
PARTS INFORMATION
Electrical/Instruments - Mercury Disposal/Recycling

Group: GENERAL
Number: 07-00-002
Date: AUGUST, 2007
Model:
ALL
Subject
DISPOSAL/RECYCLING OF MERCURY CONTAINING MATERIALS
DESCRIPTION:
This bulletin clarifies dealer responsibilities regarding the disposal/recycling requirements for mercury containing materials.
Components that contain mercury must be disposed of according to Local, State and Federal Laws.
Components that may contain mercury include backlit LCD rear seat entertainment displays, high intensity discharge (HID) lamps, and navigation
display devices.
It is the responsibility of each dealer to be aware of and comply with hazardous waste laws (including for mercury) determining how to deal with
waste and recycling matters.
For additional information on state laws and disposal/recycling programs in your state please visit this web site:
http://www.epa.gov/epaoswer/hazwaste/mercury/collect.htm.
Technical Service Bulletin # 08-BE-004 Date: 080601
Electrical - Voltage Drop Diagnostics

Group: ELECTRICAL
Number: 08-BE-004
Date: JUNE, 2008
Model: ALL
Subject:
DIAGNOSIS VOLTAGE DROP
DESCRIPTION:
Excessive resistance in high amperage circuits may result in one or more of the following symptoms:
^ Blower motor speed slow down and the radio cycles off and on.
^ Intermittent headlight dimming during deceleration.
This bulletin provides the procedure to diagnose and repair the vehicle wiring grounds.
SERVICE PROCEDURE:
1. Start vehicle and turn on headlights (including high beam), air conditioning, and set the blower to maximum speed.
2. Using a known good digital volt-ohm meter (DVOM), perform a voltage drop test on the positive battery cable, paying particular attention to
the leads to the Engine Room Junction Box (refer to photo). If the voltage drop is more than 0.2 volts on any of the leads, replace the Positive
Battery Cable.
3. Perform voltage drop test on the negative battery cable. If the voltage drop is more than 0.2 volts, repair or replace the negative battery cable.
4. Perform voltage drop check to all body ground locations in the engine compartment. Check with the positive volt meter lead on the negative
battery terminal and the negative lead to the ground locations. If the voltage drop is more than 0.2 volts, repair or replace the body ground
terminal and/or wiring assembly.
5. Perform voltage drop check to all Engine and Transmission ground straps. Check with the voltmeter positive lead on one end of the strap and
the negative lead to the opposite end. If the voltage drop is more than 0.2 volts, repair or replace the ground terminal and/or ground strap.
NOTE:
When repairing grounds, chase the bolt threads with appropriate tool, clean the harness terminal and apply a star washer between the bolt and
the terminal eyelet. Do not sand or grind paint from the body.
Normal warranty operation code and times apply.
Technical Service Bulletin # 08-SS-003 Date: 080306
Wheels/Tires - Steering Wheel Shimmy/Vibration

Group: SUSPENSION
Number: 08-SS-003
Date: MARCH, 2008
Model: ALL
Subject:
TIRE AND WHEEL VIBRATION AND RADIAL FORCE VARIATION
THIS BULLETIN SUPERSEDES TSB # 06-50-013 TO INCLUDE 2008 MODEL YEAR VEHICLES.
NOTE:
Each wheel and tire assembly is precision balanced and force match mounted before the vehicle leaves the assembly line. Dealers should not
alter the dynamic balance of any wheel unless a customer describes experiencing a tire/wheel vibration condition.
DESCRIPTION:
A customer may describe a steering wheel vibration or "shimmy" condition in the vehicle. Sources of vibration/shimmy may be from the following
conditions:
1. Wheel and tire assembly out of balance
2. Wheel out of round
3. Tire assembly stiffness variation (Radial Force Variation or RFV)
RFV (Radial Force Variation) may be defined as the amount of change in stiffness of the sidewall and footprint when a load is placed against
a tire.
Wheel and tire assembly imbalance should be addressed first because it is the most common cause of vibration. A well maintained
off-vehicle, two-plane dynamic wheel balancer can accurately correct this condition.
If a vibration or shimmy is still present after an imbalance condition is corrected, any out-of-round condition of the wheel and force variation
of the tire must be addressed.
NOTE:
All of the above conditions may be addressed at the same time if equipment is available such as the Hunter GSP 9700, which is a
two-plane wheel balancer.
For proper diagnosis, it is important that the wheel run-out and tire assembly stiffness variations be measured and, if necessary, corrected
before replacing any component(s) on the vehicle.
COMMENT:
To correct vehicle vibrations caused by wheel out-of-round and tire stiffness variations, access to a Hunter GSP 9700 or equivalent wheel
balancing machine is necessary. If you do not have access to such equipment, it may be located through the Hunter website
(www.gsp9700.com).
For information about the purchase of a Hunter GSP 9700 and Hyundai's special pricing, please visit website (http://hyundai.spx.com).
Follow the machine manufacturer's procedure to measure and correct wheel and tire assembly RFV related vehicle vibrations.
The following assembly RFV may be used as guide:
^ P-Metric passenger vehicle wheel and tire assemblies = 18 - 20 lbs or less
^ P-Metric SUV and Van wheel and tire assemblies = 24 - 27 lbs or less
NOTE:
This information is a guideline, and the RFV range accounts for machine variability.
If force match mounting the wheel and tire assembly to the above guideline cannot be achieved, it may be necessary to replace a wheel or tire
or both to correct the vibration condition (see note below before replacing any part). Since tires can sometimes become temporarily
flat-spotted, the RFV should be measured immediately after the vehicle is driven at least 10 miles. (If the RFV cannot be measured
immediately after the vehicle has been driven at least 10 miles, elevate the vehicle on a hoist with the wheels hanging to stop the tires from
flat-spotting). Tire pressure must also be adjusted to the recommended pressure shown on the driver's door or B-Pillar.
NOTE:
If the vehicle vibration condition cannot be improved to an acceptable level using the above procedure or a tire or wheel is required to be
replaced to correct this condition, contact the Hyundai Technical Assistance.
REQUEST TO CALLING TECHNICIAN:
The dealer technician must provide the following information to the Technical Assistance Line:
1. Customer description of the condition
2. VIN
3. Mileage
4. Tire size
5. Tire manufacturer
6. Tire condition
7. Wheel - alloy or steel
8. Wheel Hyundai or aftermarket
9. Imbalance values (inside and outside)
10. 1st and 2nd order RFV values in lbs
11. Wheel run-out values (radial and axial)
12. Location of the wheel on vehicle (RF, LF, RR, LR)
NOTE:
Printed copy of any of the above information will be appreciated.
Technical Service Bulletin # 08-GI-003 Date: 080701
Drivetrain - Recreational Towing Requirements

Group: GENERAL
Number: 08-GI-003
Date: JULY, 2008
Model: ALL
Subject:
DESCRIPTION:
This bulletin provides requirements for towing 2WD Hyundai vehicles equipped with manual transaxles with all four wheels on the ground, such as
may be done to tow behind a recreational vehicle.
CAUTION:
The combinations listed in the TABLE MUST NOT be towed behind a recreational vehicle with all four wheels on the ground.
MANUAL TRANSAXLE EQUIPPED 2WD HYUNDAI VEHICLE TOWING REQUIREMENTS:
NOTE:
Any Hyundai 2WD vehicle equipped with a manual transaxle may be towed with all four wheels on the ground behind another vehicle, such as a
6. Front tires are of the same size
7. Front tire pressures are equal and inflated to the recommended pressure
NOTE:
WARNING:
NOTE:
information quickly summarizes the various recommended towing procedures to be used by Hyundai dealers or by commercial truck towing
companies.Technical Service Bulletin # 08-ST-001 Date: 080730
Steering - Power Steering Pump Whine

Group: STEERING SYSTEM
Number: 08-ST-001
Date: AUGUST, 2008
Model: ALL
Subject:
SERVICE TIP - POWER STEERING OIL PUMP WHINE NOISE
DESCRIPTION:
Before replacing a power steering oil pump for a "whine" noise condition, check the oil pump reservoir filter screen for contamination. If the filter
screen at the bottom of the oil pump reservoir is clogged, it may cause the pump to aerate and cause a "whine" noise.
If the filter screen is clogged, replace the reservoir and reconfirm the condition.
The photo shows the location of the screen in the reservoir.
NOTE:
For proper inspection of the screen, it may be necessary to empty the power steering oil pump reservoir. Technical Service Bulletin #
08-SS-004 Date: 080801
Steering/Suspension - Drift/Pull Diagnosis/Repair

Group: SUSPENSION SYSTEM
Number: 08-SS-004
Date: JULY, 2008
Model: ALL
Subject:
DIAGNOSIS AND CORRECTION OF VEHICLE PULL
This bulletin supersedes TSB 05-50-012 to include 2009 models
DESCRIPTION:
Several factors may cause vehicle pull, both vehicle related and external conditions. The purpose of this bulletin is to assist in identifying the
vehicle related conditions that cause pull and how to correct those conditions.
CAUSES OF VEHICLE PULL:
Vehicle pull is the tendency of the vehicle to drift right or left while driving in a straight ahead direction on a straight road at a constant speed with
no pressure on the steering wheel. This pull or drift may be gradual and can always be compensated for by inputs through the steering wheel. One
or more of the following conditions may cause the vehicle to pull:
Non-vehicle conditions that may cause the vehicle to pull:
^ Cambered road surfaces - Most highways are built with cambered or "crowned" surfaces to drain rain water. Sometimes the road camber is
visually noticeable. Other times, it is not. The vehicle may tend to pull to the left or right, depending on the camber of the road surface.
^ Cross-winds - A sometimes overlooked, yet possible cause of steering drift is cross-winds. Side winds at higher vehicle speeds may cause
vehicle pull. Please do not rule out cross-winds when diagnosing a vehicle pull.
Vehicle pull caused by these two conditions is not related to vehicle adjustments and no repair should be made.
Vehicle conditions that may cause the vehicle to pull:
^ Tire inflation pressure - As small as a 2 pounds/square inch tire inflation pressure difference between the right and left tires may cause a vehicle
to pull. Be sure to check the tire pressure before the tires are warmed up prior to attempting more extensive diagnosis.
^ Wheel alignment - Slightly out of specification wheel alignment causes very few vehicles to pull. Therefore, if the vehicle wheel alignment has
been adjusted as close as possible to specification, DO NOT attempt to correct the vehicle pull by changing the wheel alignment angles by
bending suspension components or other non-approved methods.
^ Uneven brake adjustment - If one of the four brakes is dragging, the vehicle may pull to the side of the dragging brake. Verify that none of the
brakes are dragging and that they are adjusted correctly prior to attempting more extensive diagnosis.
^ Incorrect vehicle trim height - If the trim height of the vehicle is not equal on all sides, the vehicle may pull to the side of the lower trim height.
Check and adjust the trim height of the vehicle as necessary. Please note that a slight variation in the vehicle trim height seldom causes a
noticeable vehicle pull.
^ Tire construction - The way in which the tire is built can produce vehicle pull. An example of this is the placement of the under tread belt. An
off-center radial tire belt can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone.
To correct this condition, please use the flow chart. This chart provides the sequence of procedures designed to be performed for all conditions
of vehicle pull.
^ Tire size - Different size tires or different make of tires, on either axles, may cause a vehicle pull.Technical Service Bulletin #
08-FL-008 Date: 080811
Fuel System - E85 Fuel Usage Recommendations

Group: FUEL SYSTEM
Number: 08-FL-008
Date: AUGUST, 2008
Model: ALL MODELS
Subject:
USE OF E85 BLENDED ETHANOL FUEL
DESCRIPTION:
E85 fuel is an alternative fuel composed of up to 85 percent ethanol and 15 percent gasoline, and is manufactured exclusively for use in Flexible
Fuel Vehicles. E85 is not compatible with current Hyundai models. Use of E85 in Hyundai vehicles may result in poor engine performance or a
hard or no start condition, and damage to the vehicle's engine and fuel system.
Hyundai recommends that customers do not use fuel with an ethanol content
exceeding 10 percent. Damage resulting from the use of E85 is not covered under Hyundai warranties.
VEHICLES AFFECTED:
^ This TSB applies to all Hyundai models
SERVICE TIP:
Sample fuel from incident vehicles can be tested with the Fuel Tester Kit (J-48983). Measurements such as the alcohol % concentration and
specific gravity can be made to determine if the grade/type of fuel is correct.
Vehicle repair expenses caused by usage of E85 blended fuel are not eligible for warranty reimbursement. Repair order must explain this clearly for
customer pay work.Technical Service Bulletin # 09-AT-008 Date: 090410
A/T - Stall Test Procedures

Group TRANSAXLE
Number 09-AT-008
Date: APRIL, 2009
MODEL ALL
AUTOMATIC TRANSAXLE STALL TEST PROCEDURE
This TSB revises TSB 07-40-007 to add Genesis information
DESCRIPTION:
To diagnose a transaxle for "slipping" or Diagnostic Trouble Codes P0731, P0732, P0733, P0734 or P0735 (incorrect gear ratio), perform a stall
test using:
^ The A/T Tester Plus, P/N TCAE 125B or
^ The stall test procedure shown below.
STALL TEST PROCEDURE WITHOUT A/T TESTER:
1. Check the automatic transaxle fluid level according to the following TSB. Add ATF, if necessary, to bring the level within the "HOT" range.
^ TSB 06-40-016 - All except Veracruz and Genesis
^ TSB 07-40-004 - Veracruz only
^ TSB 08-AT-005 - Genesis Sedan V6 only
^ TSB 09-AT-001 - Genesis Sedan V8 and Genesis Coupe V6
^ TSB 09-AT-003 - Genesis Coupe 2.0L Turbo
2. Apply the parking brake and place blocks in front and behind both front wheels.
CAUTION:
Do not let anybody stand in front or behind the vehicle.
3. Start the engine and move the select lever to "D".
4. Press and hold the brake pedal, then fully depress the accelerator and record the engine speed.
CAUTION:
Do not hold the throttle fully open for more than 3 seconds. Release the throttle and allow the engine to idle in "N" for 15 seconds.
5. Confirm the stall speed is within the specifications shown in the related shop manual (approximately 2000~2900 rpm at sea level, depending on
model). If the stall speed is higher than specification, one or more clutches may be slipping.
6. Move the shift lever to "R", then repeat Steps 4~5. Go to Step 7.
7. Move the shift lever to the "Sports Mode" position (if installed), then move the lever forward to select "Gear 2". Perform Steps 4~5.
VEHICLES EQUIPPED WITH SPORTS MODE - EXCEPT VERACRUZ AND GENESIS:
This procedure tests the clutches and brakes shown above. The OD clutch is applied for 3rd, 4th and 5th gear. The RED clutch is for 5-speed
transaxle.
VERACRUZ:
This procedure tests the clutches and brakes shown above. The "C2" clutch is applied for 4th, 5th and 6th gear.
GENESIS SEDAN 3.8L V6:

This procedure tests the clutches and brakes shown above. The "C2" clutch is applied only in 4th, 5th and 6th gears. The "C4" clutch is applied for
engine braking in 1st, 2nd, 3rd and 4th gears only.
GENESIS SEDAN 4.6L V8 & GENESIS COUPE 3.8L V6:
This procedure tests the clutches and brakes shown above. The "E" clutch is applied for 4th, 5th and 6th gears.
GENESIS COUPE 2.0L:
This procedure tests the clutches and brakes shown above. The Input clutch is applied for 4th and 5th gears.
VEHICLES WITHOUT SPORTS MODE:
2007~ Elantra Sedan and 2009~ Elantra Touring (PRND32L shift pattern):
This procedure tests the clutches and brakes shown above. The OD clutch is applied in 3rd and 4th gear. The 2-4 brake is applied in 2nd and 4th
gear.
1999~01 Sonata, 1999~01 Tiburon (PRND2L shift pattern):
This procedure tests the clutches and brakes shown above. The OD clutch is applied in 3rd and 4th gear).
1995~ Accent (PRDL shift pattern).
This procedure tests the clutches and brakes shown above. The end clutch is applied in 4th gear.
Labor time for the stall test is included in 45000R00 (Replace automatic transaxle).
Technical Service Bulletin # 09-EM-001 Date: 090202
Engine - Unnecessary Crankcase Flushing

Group ENGINE MECHANICAL
Number 09-ME-001
Date FEBRUARY, 2009
Model
ALL MODELS
Subject:
UNNECESSARY ENGINE FLUSH SERVICES
DESCRIPTION:
Hyundai Motor America does not endorse or recommend engine crankcase flushing for any of its engines. Some aftermarket products and methods
used for crankcase flushing may potentially cause damage to internal engine components, including engine seals and bearings. Any damage to
engine components as a result of crankcase flushing is NOT covered under the powertrain warranty.
VEHICLES AFFECTED:
^ ALL MODELS
SERVICE INFORMATION:
Normal Maintenance Schedule
Whenever applicable, dealer service personnel should adhere to the recommended maintenance schedule outlined in the applicable Owner's Manual
and the published procedures in the Shop Manual.
Maintenance Under Severe Usage Conditions
If the vehicle is operated under severe driving conditions, then follow the maintenance schedule under severe usage conditions from the applicable
Owner's Manual.
Engine Oil APE Classification and SAE Viscosity Grades
Refer to the applicable Owner's Manual and Shop Manual for the recommended APE classification and the correct SAE viscosity grade engine oil
to be used.Technical Service Bulletin # 09-BD-003 Date: 090127
Wheels - Aluminum Wheel Cleaning And Maintenance

Group: BODY
Number: 09-BD-003
Date: JANUARY, 2009
Model: ALL MODELS
Subject: ALUMINUM WHEEL CLEANING AND MAINTENANCE

DESCRIPTION:
This TSB describes how to clean and maintain the aluminum wheels on Hyundai vehicles. The following information on wheel care may be given
to customers as needed. Hyundai has found that some vehicles equipped with wheels that have been coated with a vapor chrome finish have
exhibited surface damage from the use of harsh chemicals and improper cleaning procedures. Though these wheels have the appearance of chrome
plating, they have a painted surface similar to the exterior of the vehicle, therefore, the same care should be used when cleaning and maintaining.
RECOMMENDED CLEANING PROCEDURE:
1. Wash wheels when they are cool, in a shaded area away from direct sunlight.
2. Wash wheels with a neutral detergent or an alkaline wash soap (car soap) using a soft cleaning sponge.
3. Rinse the soap off the wheel with water spray, then dry wheels using a 100% cotton terry cloth towel, chamois or a synthetic fabric designed for
automotive detailing.
TO AVOID WHEEL DAMAGE, DO NOT USE THE FOLLOWING:
1. Abrasive soaps, cleaners, household detergents and wheel/tire dressings.
2. Abrasive polishes, chrome polishes, chemicals and acid-based cleaners.
3. Abrasive cleaning brushes and steel wool.
4. Some automatic car washes may also cause damage to the vapor chrome finish.
5. Car wash chemical strength cleaners along, with brush agitation could damage the finish.
NOTE: Wheels that are found to be damaged by incorrect cleaning may be considered to have been damaged by abuse and will not be covered by
the vehicle's warranty.
APPLICABLE VEHICLES:
MODELS: All vehicles equipped with aluminum wheels
Technical Service Bulletin # 09-AT-006 Date: 090311
A/T - Specified ATF and Additive Usage Information

Group AUTOMATIC TRANSAXLE
Number 09-AT-006
Date: MARCH, 2009
Model
ALL
Subject
HYUNDAI SPECIFIED ATF AND ADDITIVE USAGE
DESCRIPTION:
Hyundai Motor Company approves of the use of only the ATF specified in the vehicle's owner's manual. Use of other ATF may result in improper
shift quality or other driveability issues.
Hyundai Motor Company does not approve of the use of any aftermarket ATF additives.
Hyundai Owner's Manuals state:
"Use only Hyundai Genuine ATF or other brands meeting the specification approved by Hyundai Motor Company."
The approved ATF and the ATF level checking procedure are shown above.
Technical Service Bulletin # 08-BE-012 Date: 081125
Accessories - Programming Homelink(R) To Garage Opener

Group: ELECTRICAL
Number: 08-BE-012
Model: ALL
Subject: PROGRAMMING HOMELINK MIRROR TO GARAGE DOOR RECEIVERS WITH ROLLING CODE TECHNOLOGY
DESCRIPTION:
Several Hyundai models come equipped with HomeLink rearview mirrors.
Programming the HomeLink mirror to operate a standard remote-controlled garage door opener requires that the owner have one of the original
hand-held remotes. In the case of "rolling code" receivers, access to the garage door receiver (usually located on the garage door motor housing) is
also required.
Most garage door openers manufactured after 1996 incorporate rolling code, or "anticode grabbing" technology. This technology uses a coding
algorithm that allows the transmitter to send a different authentication code each time the remote button is pressed, never repeating the same code
twice.
This bulletin provides programming instructions for rolling code garage door openers.
A copy of this bulletin should be made available to vehicle owners that are experiencing difficulty when programming their rolling code garage
door opener.
NOTE:
Some vehicles may require the vehicle ignition to be turned ON or to the ACC position for training and/or operation of HomeLink. It is also
recommended that a new battery be installed in the hand held transmitter of the device being trained to HomeLink for accurate transmission of
the radio frequency.
CAUTION:
Before programming HomeLink to a garage door opener, make sure that people and objects are out of the way of the device to prevent harm or
damage.
Your motorized garage door will open and close while you are programming HomeLink. Do not program HomeLink if people or pets are in the
path of the door or gate. A moving garage door can cause serious injury or death to people and pets or damage to objects.
Do not run the vehicle's engine while programming HomeLink. Vehicle exhaust contains carbon monoxide, a dangerous gas. Exhaust gas can cause
serious injury or death. When programming a garage door opener, it is advised to park outside of the garage.
Do not use HomeLink with any garage door opener that lacks safety stop-and-reverse features as required by U.S. federal safety standards (this
includes any garage door opener model manufactured before April 1, 1982). A garage door that cannot detect an object, signaling the door to stop
and reverse, does not meet current U.S. federal safety standards.
PROCEDURE:
1. For first time training, press and hold the two outer HomeLink buttons, releasing only when the HomeLink indicator light begins to flash after 20
seconds.
NOTE: Do not perform this step when training the additional HomeLink buttons.
2. Position the hand-held transmitter 1-3 inches away from the HomeLink mirror, keeping the HomeLink indicator light in view.
3. Using both hands, simultaneously press and hold both the desired HomeLink button and the hand held transmitter button.
DO NOT release until the HomeLink indicator light flashes slowly and then rapidly.
When the indicator light flashes rapidly, both buttons may be released. The rapid flashing indicates successful training and the procedure is
complete. This also indicates that the garage door opener does not use rolling code technology.
Note: The garage door may open or close during this step.
Steps 4 through 7 are only necessary if the HomeLink button appears to be transmitting after step 3, but the garage door does not operate.
4. Press and hold the trained HomeLink button and observe the indicator light.
If the indicator light is solid/continuous, training is complete and your device should activate when the HomeLink button is pressed and released.
If the indicator light blinks rapidly for 2 seconds and then turns a solid/continuous light, proceed with the following training instructions for a
rolling code device. A second person may make the following steps quicker and easier. It is recommended that a ladder or similar device be used to
obtain access to the motor housing. Do not stand on the vehicle to perform the next steps.
5. At the garage door opener receiver (motor housing) in the garage, locate the "learn" or "smart" button (usually near the hanging antenna wire
attached to the unit). If there is difficulty locating the training button, refer to the garage door opener's manual.
6. Press and release the "learn" or "smart" button (the name and color of the button may vary by manufacturer).
NOTE: Once the button is pressed, there are 30 seconds in which to initiate the next step.
7. Return to the vehicle and firmly press and hold the trained HomeLink button for two seconds and release. Repeat the "press/hold/release"
sequence up to 3 times to complete the training process. If successful, your garage door should open or close during this step.
If the vehicle owner continues to have difficulty programming their HomeLink mirror, please have them contact HomeLink customer service
directly at 1-800-355-3515 or www.homelink.com for further assistance.
PROCEDURE COMPLETE
Technical Service Bulletin # 09-BD-011 Date: 090901
Body - Sunroof Creaking/Ticking Noises

Group BODY
Number 09-BD-011
Date SEPTEMBER, 2009
Model ALL
Subject
SUNROOF CREAK / TICK NOISE REPAIR
DESCRIPTION:
Some vehicles may exhibit a creak and/or ticking type noise from the sunroof glass panel when the vehicle is driven on uneven to rough roads
and/or when opening the sunroof. The noise can be duplicated statically by applying pressure to the rear center section of the sunroof glass panel
with the sunroof in the closed position.
Model: All Models
PARTS INFORMATION
SERVICE PROCEDURE:
1. Tilt sunroof glass open to the fully tilt position to expose the rear section of weatherstrip.
2. Spray dry silicon lubricant onto the sunroof glass panel weather-stripping.
3. Position the sunroof panel in the fully closed position and confirm that the noise is eliminated.
NOTE:
Use a clean towel to remove excess lubricant and ensure the vehicle is well ventilated prior to returning vehicle back to the customer.
Normal warranty applies.
Technical Service Bulletin # 09-FL-006 Date: 090701
Emissions - Supplemental EVAP System Diagnostics

Group
FUEL SYSTEM
Number
09-FL-006
Date
JULY, 2009
Model
MULTIPLE MODELS
Subject
EVAPORATIVE EMISSION SYSTEM DIAGNOSTIC INFORMATION
DESCRIPTION:
This bulletin augments currently available service information for the evaporative emissions system.
VEHICLES AFFECTED:
^ All Hyundai models from 1996 Model Year to current, which are OBD-II compliant.
SYSTEM OVERVIEW:
The Evaporative (EVAP) Emissions System prevents the release of hydrocarbon (HC) vapors from the fuel system into the atmosphere.
Evaporated vapors from the fuel tank are collected in the charcoal canister, where the activated carbon surface captures and stores the vapors. Fuel
vapors passing over and through the activated carbon surface are absorbed and the remaining volume of fresh air vents through the normally-open
Canister Close Valve (CCV) and the vent system.
During an EVAP purge event commanded by the Powertrain Control Module (PCM), the normally-closed Purge Control Solenoid Valve (PCSV) is
energized to open. As the PCSV opens, the intake manifold vacuum from the engine draws fresh air through the canister from the vent system while
the absorbed fuel vapors from the charcoal canister are metered into the engine as part of the combustible mixture.
EVAP SELF-DIAGNOSTIC CHECKS:
During normal engine operation and when enabling criteria are met, EVAP self-diagnostics are performed by the PCM to check the system
function.
NOTE:
If any portion of the self-diagnostic test is executed and fails, then all further EVAP system checks are suspended. Each diagnostic test must run
and pass without failure before proceeding to the next series of tests.
^ The first check performed is to confirm if the PCSV is closing completely or is leaking vacuum. Resulting DTC is P0441 (Purge Flow Incorrect).
^ If the system failed the above PCSV DTC P0441 test, then a supplemental diagnostic check will be performed which checks for P2422 (Vent
Path Restricted). This diagnostic is accomplished by opening the normally closed purge valve and monitoring the fuel tank pressure sensor for an
increase in vacuum. If the measured vacuum exceeds the threshold, then DTC P2422 is set to indicate a vent system restriction. (In some
systems, P0446 may set instead.)
^ The second check performed is the P0455 (Large Leak Detect). This diagnostic is accomplished by closing the normally-open canister close
valve (CCV) and opening the normally-closed purge valve while monitoring the fuel tank pressure sensor signal until -10 in H2O (vacuum) is
achieved. Once the FTPS achieves target vacuum, the PCSV is commanded "closed" and the vacuum decay is measured. If a leak in excess of a
0.100" hole is detected, then DTC P0455 is set.
^ The third check performed is the P0442 (Small Leak Detect). This diagnostic follows the same process as the Large Leak Detect described
above, however, the threshold values are reduced. If a leak in excess of a 0.040" hole is detected, then DTC P0442 is set.
^ The fourth check performed is the P0456 (Very Small Leak Detect). This diagnostic follows the same process as the two Leak Detect checks
described above, however, the threshold values are the lowest. If a leak in excess of a 0.020" hole is detected, then DTC P0456 is set.
EVAP SYSTEM RELATED DTC - POSSIBLE CAUSES:
P0441 (Incorrect Flow Detected)
This code may set if the system detects vacuum leaking through the purge valve at idle.
^ Purge Control Solenoid Valve may be stuck open or leaking internally.
P0455 (Large Leak), P0442 (Small Leak), P0456 (Very Small Leak)
There are multiple potential causes and a manual leak check may be required to determine the exact location of the detected physical leak (Refer to
TSB 02-30-001).
^ Check the fuel cap gasket and the fuel filler neck sealing interface. Check tightening click and removal effort of the fuel cap (there may be a
partial seal if removal effort is too light).
^ Check for loose connections at the interface of hoses, clamps, quick connectors, and O-rings. In addition, check for leaks at hoses, fuel pump top
plate, or canister.
^ PCSV (low flow/leaking/reverse connected) or CCV (leak when energized) issues.
P2422 (Vent Valve Stuck Closed), P0446 (Vent Control Circuit Malfunction)
^ Foreign material in vent path (dirt, spider webs, kinked line). It may be required to remove both ends and use shop air or other methods to clear
the obstruction.
^ CCV (stuck closed) mechanically or CCV filter assembly is plugged with dirt, preventing airflow from atmosphere into and through the canister.
NOTE:
Under extreme conditions, such as driving on dusty roads, or unpaved roads for prolonged periods, the CCV filter will require more frequent
replacement during routine maintenance.
Technical Service Bulletin # 09-AT-013 Date: 090701
A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N

Group
TRANSAXLE
Number
09-AT-013
Date
JULY, 2009
Model
ALL EXCEPT VERACRUZ AND GENESIS
Subject
AUTOMATIC TRANSAXLE RANGE SWITCH DIAGNOSTIC TROUBLE CODES P0705, P0707, P0708
This TSB supersedes TSB 03-40-013 to add repair information (Steps 2-3).
DESCRIPTION:
An improperly adjusted or improperly operating range switch may result in the following conditions:
^ Diagnostic trouble codes:
^ P0705 - Range switch signal problem
^ P0707 - Range switch - open circuit
^ P0708 - Range switch - short circuit or multiple inputs
^ Malfunction Indicator Light (MIL) illuminated
^ Impossible engine start in "P" or "N"
This TSB provides information concerning the proper adjustment and diagnosis of the transaxle range switch.
PARTS INFORMATION
Service Procedure
1. Attach a GDS and check for DTC in both the "Engine" and "Automatic Transaxle" menus. Go to Step 2 for 2000-02 Accent or Step 3 for
2006-Sonata. For other vehicles, go to Step 4.
2. For 2000-2002 Accent: Check according to TSB 03-40-001. Go to Step 4.
3. For 2006-Sonata, follow steps a, b, c below, then go to Step 4.
a. Check the rear combination lamp ground bolts for tightness and good electrical contact (refer to applicable ETM, "Tail, Parking & License
Lamps" section). Go to Step b.
b. For 2006-Sonata: Remove the center console cover and check for contamination on the M40 connector to the sports mode switch. If so, clean
and repair the connector as necessary. Go to step c below.
c. For 2006-07 Sonata: Remove the front pillar cover and verify the harness is properly routed near the clip. Repair the harness as necessary. Go
to Step 4.
4. Attach a GDS and select vehicle, "A/T" menu, "Current Data" and "Shift Lever Switch".
5. Move the shift lever and confirm the GDS reads the gear shift position as shown above. If so, the harness currently does not have an open or
short circuit between. the PCM/TCM and range switch.

7. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Check that the drill or bolt fits into the adjustment holes.
^ If so, go to Step 8
8. Inspect the connector to the range switch for a bent pin or pin not fully inserted and related wiring for an open or short circuit. If OK, follow the
repair procedure below:
RANGE SWITCH REPLACEMENT:
9. Install the new range switch and loosely install two 10 mm bolts.
10. Attach the lever and nut. Tighten the nut to specification. Go to Step 11.
Specification: 11-13 lb ft. (15-18 Nm, 150-180 kg.cm)
RANGE SWITCH ADJUSTMENT:
13. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Tighten the two 10 mm mounting bolts to specification.
Remove the 5mm drill or M5 bolt.
14. Move the shift lever to the "N" position. Attach the shift cable to the lever and install the nut. Tighten the nut to specification.
15. Attach the connector.
16. Drive the vehicle two key-on to key-off drive cycles, including shifting to gears D, 3, 2, L (if equipped) and R. If the:
^ DTC does not reset, return the vehicle to the customer.
^ DTC resets, repair or replace the control harness. If the DTC sets again, replace the TCM.
Computers/Controls - OBDII DTC List

OBD-II trouble code table
This special issue of Tech Net Times features a listing of general Diagnostic Trouble Codes and their explanation. Included in this bulletin is a
special Hyundai Diagnostic Trouble Code section. Keep this issue on hand for a handy DTC reference guide. Don't forget to visit
www.hmaservice.com for further Hyundai service information.
^ The list above covers all SAE defined standard P zero codes allocated at the time of publication.
^ All OBD-II codes starting with P zero have standard meanings irrespective of vehicle make or model.
HYUNDAI SPECIFIC TROUBLE CODES

SRS DIAGNOSTIC TROUBLE CODE TABLE

BCM - ETACS
FATC/ABS/TCS/ESP/ALHS CODES
FATC CODES
Technical Service Bulletin # 10-SS-003 Date: 100215
Brakes - Brake Fluid Adding/Changing Precautions

Group BRAKES
Number 10-SS-003
Date FEBRUARY, 2010
Model ALL
Subject
BRAKE FLUID PRECAUTIONS - ADDING OR CHANGING FLUID
DESCRIPTION:
This bulletin provides guidelines that should be followed before removing the brake fluid reservoir cap when adding or changing brake fluid.
IMPORTANT:
Make sure to completely remove foreign substances from around brake fluid reservoir and cap before opening the reservoir cap. Not following this
may cause contamination of brake fluid.
VEHICLES AFFECTED:
All models
1. SERVICE PROCEDURE:
^ Location of brake reservoir cap
There are two potential locations for the brake fluid reservoir shown above.
HOW TO REMOVE FOREIGN SUBSTANCES FROM AROUND THE BRAKE FLUID RESERVOIR CAP:
1. If the brake fluid reservoir cap is located in front of cowl top cover, first wipe foreign substances off the brake fluid reservoir and its cap and then
open the cap to add or change brake fluid.
2. If the brake fluid reservoir cap is located under cowl top cover, first wipe foreign substances off the lower surface of the cowl top cover, the
brake fluid reservoir and its cap and then open the cap.
3. If brake fluid reservoir is equipped with oil filter, add or change brake fluid with the oil filter inserted. DO NOT remove the oil filter while filling
brake fluid.
A/T Controls - DTC Diagnostic Information

Automatic Transaxle Diagnosis
Only the Diagnostic Trouble Codes (DTC) listed indicate a possible internal transaxle concern. All other DTC are due to electrical or component
concerns. Refer to TSBs:
^ Bottom pan transaxle: 04-40-020 or 03-40-021, 'Automatic Transaxle DTC List"
^ Side pan transaxle: 04-40-019 or 03-40-020, "Automatic Transaxle DTC List"
Please call the Hyundai Technical Assistance Line if you need additional information.Technical Service Bulletin # 10-AT-002 Date:
100209
A/T - Specified ATF And Additive Usage

Group AUTOMATIC TRANSAXLE
Number 10-AT-002
Date FEBRUARY, 2010
Model ALL
SUBJECT
HYUNDAI SPECIFIED ATF AND ADDITIVE USAGE
DESCRIPTION:
Hyundai approves the use of only the ATF specified in the vehicle's owner's manual. Use of other ATF may result in improper shift quality or other
driveability conditions.
Hyundai does not approve of the use of any aftermarket ATF additives.
The approved ATF and the ATF level checking procedure are summarized below:
HYUNDAI SPECIFIED ATF
NOTE:
SPH-IV and SP-III are not interchangeable.
A/T - No Movement In Drive/Reverse

AUTOMATIC TRANSAXLE - NO MOVEMENT IN DRIVE OR REVERSE GEAR
MODEL: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear follow the procedure shown below:
REPAIR PROCEDURE:
1. Check for DTC in both the "Engine" and "Automatic Transaxle" menus:
^ If DTC are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DTC are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide conclusive results, remove the oil pan and check
for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not replace the transaxle. SPIII may change color to a
dark brown after 10,000 to 25,000 miles in service. This change is normal for this type of ATF.
VERIFY THE RANGE SWITCH ADJUSTMENT:

4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the drill or bolt fits into the adjustment holes.
^ If so, go to Step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two 10 mm mounting bolts to specification.
Specification: 7-8 ft.lb
(10-12 Nm, 100-120 kg.cm)
8. Move the shift lever to the "N" position. Attach the

shift cable to the lever and install the nut. Tighten the nut to specification.
Specification: 9-10 ft.lb
(12-13 Nm, 120-130 kg.cm)
Remove the 5 mm drill or M5 bolt.
VERIFY THE SIGNAL FROM THE RANGE SWITCH:
9. Attach a Hi-Scan Pro and select:
^ "Hyundai Vehicle Diagnosis"
^ Vehicle
^ Automatic Transaxle" menu
^ "Current Data" menu
^ "Select Lever Switch" and "Shift Position:
10. Move the shift lever to Reverse.
^ Monitor "Select Lever Switch".
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully inserted.
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ Monitor "Shift Position" and "Select Lever Switch".

^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch. Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully inserted.
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
12. Install the A/T Tester, P/N 09450-AT000, to the vehicle:
^ Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1, 2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottompan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the solenoid. Shift the transaxle to "R".
^ If no movement replace the transaxle.
^ If the vehicle moves check the harness connector at the TCM and the solenoid for a bent pin or pin not fully inserted. Check the wiring harness
for an open or short circuit.
^ If no problem is found swap a TCM from a similar vehicle and test for movement in Drive and Reverse. If the vehicle moves in Drive and
Reverse replace the TCM.
Applicable Warranty Applies.

Engine, Drivetrain - Gray RTV Sealer Update Information

Number: 10-EM-002
Date: MAY 2010

Model: ALL MODELS
Subject
HYUNDAI GRAY RTV SILICONE GASKET MAKER
UPDATED PRODUCT INFORMATION
DESCRIPTION:
This bulletin provides updated product information regarding Hyundai Gray RTV Silicone Gasket Maker and its applicable use.
VEHICLES AFFECTED:
^ ALL MODELS
PARTS INFORMATION:
Hyundai Gray RTV (P/N 00232-19039) is now the replacement service product for previous liquid gasket applications.
NOTE:
^ Does not require a Caulking Gun to apply
^ For use in sealing against oil and coolant leaks
^ Outperforms conventional sealants in critical applications
^ Performs well at low and high temperatures
^ Sensor safe
SERVICE INFORMATION:
1. Prior to applying the RTV Silicone Gasket Maker for reassembly, the following must be done to ensure a properly sealed assembly.
^ Thoroughly remove any old sealing material residue from the mating surfaces with a gasket scraper.
IMPORTANT:
Avoid using any abrasive media such as Scotch~Brite(TM) or ROlOC(TM) disc pads, since the abrasive product remnants can contaminate
surrounding internal engine components.
^ Using a degreaser applied to a clean shop towel, wipe off any oil or coolant from the mating surfaces.
^ Apply RTV Silicone Gasket Maker to a dry surface.
2. Refer to the applicable section of the Shop Manual for the sealant BEAD WIDTH specification.
^ Apply a continuous bead of sealant at the specified bead width to prevent oil leakage.
^ The part must be assembled within 5 minutes after the sealant has been dispensed.
3. Refer to the applicable section of the Shop Manual for the TIGHTENING TORQUE specification.
4. After assembly, wait at least 30 minutes before filling with oil or coolant, performing any pressure testing, or engine starting.
Normal warranty applies, if applicable.
Engine - Oil Pump Replacement Guidelines

Number: 10-EM-003
Date: JUNE 2010
Model: ALL MODELS
Subject
ENGINE OIL PUMP REPLACEMENT GUIDELINES
DURING ENGINE REPLACEMENT
DESCRIPTION:
Follow the guidelines outlined in this bulletin to install a new oil pump after an internal engine repair or engine short block replacement.
NOTE:
A new or remanufactured engine sub-assembly (long block) is shipped with a new oil pump already installed, so this bulletin does not apply to
the installation of new or remanufactured engines.
^ ALL MODELS
PARTS INFORMATION:
^ Examples of the Short Engine Assembly (Short Block)
^ Examples of the Engine Oil Pump Assembly
NOTE:
Refer to appropriate Parts Catalogs for the applicable part numbers and descriptions of the related parts.
INSPECTION PROCEDURE AND GUIDELINES:
1. Inspect the incident engine using the ENGINE DIAGNOSIS WORKSHEET.
NOTE:
Refer to TSB 08-EM-004 (Remanufactured Engine Program) for details. Depending on the engine diagnosis, the results may not necessitate a
short or long block replacement to resolve the condition.
2. After completing the Engine Diagnosis Worksheet, determine the necessary action for repair.
3. If a short block replacement has been determined as the repair action with any of the following conditions, then ALWAYS replace the oil pump
with a new one:
^ Low or no oil pressure
^ Excessive metallic/foreign debris found inside the oil pan or oil pick-up screen
^ Continuous engine knocking noise (after isolating the accessory drive such as power steering, NC compressor, water pump, etc.)
^ Engine friction damage such as piston/cylinder wall scuffing, main/rod bearing/ journal scuffing, overly worn thrust bearing, or seizing of
rotating components
^ Engine overheat caused internal engine damage
4. If a short block replacement is not required and none of the existing conditions from Step 3 have been found, refer to the following inspection
points of the engine oil pump prior to reuse:
^ Turn the oil pump by hand (rotor/sprocket) to confirm it can be rotated freely without much resistance. Replace if internal binding damage
is observed.
^ Visually inspect the condition of the front main oil seal in the oil pump (for engines using a front case assembly oil pump) for wear, tear, or
leaks. Replace the front main oil seal if necessary to ensure a proper seal.
NOTE:
If the front main oil seal is found partially pushed out from the front case assembly, check if there is excessive crankshaft thrust endplay.
^ Visually inspect and clean the Oil (Pickup) Screen Assembly. Replace if damaged.
^ (For engines using front case assembly oil pumps) Inspect and re-tighten (if necessary) the machine screw fasteners of the oil pump cover.
^ (For engines using front case assembly oil pumps) Inspect the connection between the front case assembly and the oil screen assembly.
Replace the oil screen gasket if necessary. Re-tighten (if necessary) the bolt fasteners of the oil pickup screen.
NOTE:
Proper sealing of the oil pump cover and the oil pickup screen to the oil pump front case body is important for proper oil pressure delivery
during engine operation.
This bulletin provides additional service information during engine diagnosis and repair.
Normal warranty applies.Technical Service Bulletin # 10-AT-008 Date: 100413
A/T - Remanufactured Auto. Trans. Program

Group: AUTOMATIC TRANSMISSION
Number: 10-AT-008
Date: APRIL 2010
Model: ALL
Subject
REMANUFACTURED AUTOMATIC TRANSAXLE
(ATM) PROGRAM
This TSB supersedes TSB 09-AT-007 to add 2010~ Tucson, 2010~ Santa Fe, 2011~ Sonata and 2011~ Azera.
DESCRIPTION:
The automatic transaxle warranty repair policy authorizes in-dealership repairs of the following components for both OEM (new) and
remanufactured automatic transaxles:
NOTE:
Repair/replace the following components according to the related shop manual or TSB. DO NOT REPLACE THE TRANSMISSION.
ALL EXCEPT 6-SPEED AUTOMATIC TRANSAXLE VEHICLES:
NOTE:
Call Techline before replacing a 6-speed transmission.
6-SPEED ATM FOR 2010 TUCSON & SANTA FE, 2011 SONATA AND AZERA:
6-SPEED AUTOMATIC TRANSAXLE FOR VERACRUZ:
6-SPEED AUTOMATIC TRANSMISSION FOR GENESIS SEDAN V6:
6-SPEED ATM FOR GENESIS SEDAN V8 & GENESIS COUPE V6:

5-SPEED AUTOMATIC TRANSMISSION FOR GENESIS COUPE 2.0L TURBO:
NOTE:
Second and subsequent remanufactured ATM replacements on the same VIN require Tech Line review prior to repair and DPSM
approval/authorization for claim payment.
TRAINING:
The ATM Diagnosis and Certification Course (# SVC AT28) provides detailed instructions on how to properly diagnose and when to repair or
replace an ATM. DPSM approval is necessary when installing remanufactured transaxles if your dealership does not currently employ a technician
who has completed this course.
AFFECTED MODELS:
This program applies to all models.
^ Hyundai Transmission Cooler Flush (aerosol), P/N 00232-19021
^ Hyundai Automatic Transaxle Tester PLUS (Kent-Moore # TCAE 125B)
^ GDS (Kent-Moore # J-47439)
DIAGNOSIS PROCEDURE:
1. The Service Advisor opens a Repair Order (R.O.) documenting the customer's detailed comments. A road test by a technician or Service
Advisor may be necessary to verify the customer's description.
2. The Service Advisor carefully completes the top section of the ATM Diagnosis Worksheet (P/N NP150-07006).
NOTE:
The ATM Diagnosis Worksheet can be downloaded from the website:
^ "Documents/Resources"
^ "Service"
^ "ATM Diagnosis Worksheet.

3. The ATM Diagnosis Worksheet and shop copy of the R.O. are dispatched to the technician. (The remaining copies of the R.O. can be
distributed according to established dealership procedures.)
4. The technician follows the Diagnostic Flow Chart to assist in the diagnosis of the ATM and to make a repair/replace decision. The technician
enters the appropriate Condition Code from the list on the back of the worksheet.
NOTE:**Diagnostic trouble codes and ATM Tester results must be recorded on the ATM Diagnosis Worksheet whenever the GDS or ATM Tester
is used.
5. If it is determined that a remanufactured unit must be ordered and installed, the technician must obtain the Service Manager's approval and
signature on the Worksheet. The technician must call Techline for case review for a 6-speed automatic transaxle or 2nd reman for the same
VIN.
6. The technician sends both the Worksheet and the R.O. to the Parts Department.
7. The Parts Department orders a remanufactured ATM from the facing PDC and retains the R.O. and Worksheet, filed by R.O. number.
8. The Parts Department receives a remanufactured ATM, shipped prepaid in a reusable box, and provides the ATM to the technician.
NOTE:
Retain the reusable box and use to return the removed ATM and torque converter to the remanufacturing center.
A complete package of forms is included with each remanufactured ATM unit as shown below:
^ Core Return Checklist
^ Parts Bulletin 1307 - "Reman Core Return Program Reminders
9. The Parts Department completes all required fields of information on the Core Return Checklist. Failure to do so will result in a debit.
10. The technician completely drains all fluids and removes the ATM and torque converter from the vehicle.
NOTE:
11. Flush the transaxle oil cooler and hoses using Hyundai Transmission Cooler Flush (P/N 00232-19021). Follow instructions in TSB #
07-40-011.
NOTE:
*The ATM oil cooler and hoses must be flushed prior to installation of the remanufactured ATM. If a thorough flushing is not performed, the
remanufactured ATM can be contaminated by debris left in the cooler and hoses, resulting in shop comebacks and possible claim chargeback.
12. Install the remanufactured ATM according to the appropriate shop manual. Fill the ATM to the specified level according to the procedure in
the shop manual or TSB.
13. Secure the torque converter to the removed ATM using the torque converter retaining strap and bolts removed from the remanufactured ATM.
14. Install all plugs removed from the remanufactured ATM onto the removed ATM before packaging to prevent residual fluid from leaking.
15. Place the top copy of the ATM Diagnosis Worksheet and the top copy of the Core Return Checklist in the plastic bag provided with the
remanufactured ATM and close the envelope securely. Ensure both forms are completely filled out.
NOTE:
Failure to properly complete and/or return the designated Core Return Checklist and ATM Diagnosis Worksheet will result in a $50.00
reduction of the core credit and/or chargeback of your warranty claim.
16. Place the removed ATM into the shipping container provided with the remanufactured ATM. Secure the lid with the retaining straps.
NOTE:
Freight charges are prepaid by HMA for returning the removed ATM to the remanufacturing center, when the request is submitted through
"RETURN CORES" on DCS online (see Parts Bulletin 1307 "Reman Core Return Program Reminder") and the ATM is shipped via
ROADWAY; HMA's approved carrier. DO NOT SUBMIT A WARRANTY CLAIM FOR THESE CHARGES.
17. Retain the bottom copy of the Core Return Checklist in the dealership's Parts Department, filed by the repair order number indicated in the top
right hand corner of the checklist.
18. Retain the canary copy of the ATM Diagnosis is Worksheet together with the shop copy of the R.O. in the dealership's service files.
19. The remanufacturing center receives the removed ATM, Core Return Checklist and ATM Diagnosis Worksheet.
20. The dealer is reimbursed for the core ATM.
NOTE:
If an incorrect transaxle has been ordered and not installed, you may return it to the PDC through DCS using the new 45-day BC Return
Program.
If an incorrect transaxle has been installed, it must be returned to the remanufacturer. Please write "ordered in error" or "damaged" in the space
for the old ATM serial number on the "Core Return Checklist".
HMA may deny/chargeback all portions of ATM claims and/or core credits on remanufactured units if:
^ Oil cooler was not properly flushed, causing damage to the remanufactured ATM
^ Remanufactured ATM was damaged due to:
^ Improper handling
^ Improper installation/removal
^ Improper packaging
^ No trouble found/incorrect diagnosis
^ Comeback repair/incorrect diagnosis

^ Incomplete or missing Core Return Checklist and/or ATM Diagnosis Worksheet
NOTE:
NOTE:
Dealer Parts Department accepts full responsibility for ensuring that transaxles sold over the counter:
^ Have an ATM Diagnosis Worksheet that is completely and accurately filled out.
^ The ATM oil cooler is flushed to HMA specifications using Hyundai Transmission Cooler Flush (P/N 00235-18100).
^ Genuine Hyundai transmission fluid is used to refill the ATM.
PARTS INFORMATION:
NOTE:
See current LTS for model application.
NOTE:
The warranty information listed below can be claimed as additional operation codes if these diagnosis operations were performed and required
the use of the A/T Tester, Hi-Scan Pro and/or GDS.
Technical Service Bulletin # 10-BR-001 Date: 101011
Brakes - Service Practices & Recommendations

Group BRAKES
Number 10-BR-100
Date OCTOBER, 2010
Model ALL
Subject
BRAKE SERVICE BEST PRACTICES RECOMMENDATIONS
This TSB supercedes 10-SS-005 to include grease recommendations and brake service best practices.
DESCRIPTION:
This bulletin provides best practice recommendations for performing any brake service.
All models
TOOLS RECOMMENDED
PARTS RECOMMENDED
SERVICE PROCEDURE RECOMMENDATIONS:
BRAKE ROTOR RESURFACING
NOTE:
Always follow the brake lathe manufacturer's recommendations for proper machining.
NOTE:
It is recommended to use an "on-car" brake lathe.
NOTE:
For more information on brake disc service, refer to the applicable vehicle shop manual.
^ When measuring the brake disc for minimum service thickness and run-out, be sure to remove all surface contamination and corrosion. This will
ensure an accurate measurement.
^ Measure the disc thickness at 8 points (every 45 degrees). Measure at the same distance (~5mm/0.2") inboard of the outer edge of the disc.
Record these measurements on the repair order sheet.
IMPORTANT:
Measure the rotor thickness BEFORE and AFTER machining to ensure the disc is within specification.
^ After machining, re-install rotor (if removed) and caliper. Then, inspect disc brake run-out by mounting a dial indicator so that it touches the
brake disc about 5mm/0.2" inboard of the outer edge. Record the measurement on the repair order sheet. Refer to the applicable vehicle shop
manual for run-out tolerance.
^ When re-installing the wheels, tighten lug nuts in a star pattern. Tighten to the correct torque specification using a torque stick.
BRAKE CALIPER SERVICE BEST PRACTICES

Technical Service Bulletin # 10-EE-003 Date: 100827
Electrical - Battery Testing/Equipment/Warranty Info.

Number: 10-EE-003
Date: AUGUST 2010
Model: ALL MODELS
Subject
GR8 DIAGNOSTIC BATTERY TESTER/CHARGER TOOL & NEW BATTERY WARRANTY POLICY
DESCRIPTION:
The Midtronics GR8-1270 Diagnostic Battery Tester/Charger Assembly launches in August 2010 as a new Hyundai required tool. A new Hyundai
Battery Warranty Policy requires that GR8 be used for all battery warranty claims according to procedures outlined by the service procedure of this
bulletin. Claims based on the Midtronics MCR-570 handheld tester will no longer be accepted.
This bulletin describes how to use the GR8 for battery related warranty repair work. The GR8 is a state of the art tool that checks battery health,
then performs a reliable intelligent safe charge which can quickly restore some batteries to good condition. For example a dead battery that has not
been at a low state of charge for a long period, may be fully revived within 1.5 hours and not make replacement necessary.
Basic Operation and Battery Warranty Policy using GR8:
1. Perform a quick test in the Battery Test mode. If the Battery Test mode provides a "Replace Battery result the battery can be replaced without
further steps.
2. If the Battery Test mode produces a "Charge and Retest result, you are then required to conduct a Diagnostic Charge that will determine
whether the battery is able to be brought to a "Good Battery condition by a full GR8 charge. If the initial diagnostic charge test finds that the
charge will not revive the battery it usually will indicate "Replace Battery on average within 20 minutes.
3. Should the battery pass the "Diagnostic Charge test, it will continue charging to full battery charge condition (which can take up to 1.5 hours)
and indicate "Good Battery" when completed successfully.
4. The GR8 produces printouts of the results in both the Battery Test and Diagnostic Charge modes. Both printouts must be attached to the
warranty repair order with proper VIN and RO number entered via GR8's keyboard.
NOTE:
This new Battery Warranty Policy requires you to always perform a Diagnostic Charge after a Battery Test result of "Charge and Retest".
GR8 Diagnostic Battery Tester/Charger Assembly:

GR8 Battery Tester Unit:

Performs battery testing and initial control of the diagnostic charger. Tester can be used independent of the charger unit after a battery charge is in
process. The cable from the base may be disconnected and wireless communication exists to the Charger unit. Cable should be reconnected when
docked on the charger.
CAUTION:
Either the small Battery Tester clamps or large Charger clamps can be connected to a battery at a time.
CAUTION:
NEVER connect both sets of small and large clamps to a battery as it can cause internal damage to the GR8 assembly!
SERVICE PROCEDURE:
First Step - Battery Test (always the initial test):
1. Press the power button on the GR8 if the Battery Tester unit is docked on the Charger unit. You should hear the fan come on in the Charger unit
and Tester unit display will light up.
2. Connect only the Battery Tester unit's small clamp set to the vehicle's battery making sure that the black clamp is connected to the battery
negative terminal and the red cable's clamp is connected to the battery positive "+ terminal. GR8 display will warn if you connected it
backwards.
NOTE:
For Genesis & Equus connect Battery Test or Charger clamps directly to the battery in the rear trunk, not to engine underhood jumper terminals.
3. Follow these screen by screen instructions from left to right of each row. This example shows screens that will occur for battery condition of
"Charge & Retest":
NOTE:
Always print out the Battery Test result to attach to the Repair Order.
4. Follow directions of this table based on result of Battery Test (first column). PRINT results at Battery Test and then after Diagnostic Charge:
Second Step - Diagnostic Charge if Battery Test result was "Charge and Retest":
5. Connect only the Charger unit's large clamp set to the vehicle's battery making sure that the black clamp is connected to the battery negative
terminal and the red clamp is connected to the battery positive "+" terminal. GR8 display will warn if you had connected it backwards.
6. Perform following instructions showing the GR8 screens (as shown from left to right of each row) that will occur when a "Good Battery" is
reached after charging:
NOTE:
When the Diagnostic Charge results in "Good Battery" you must attach print tickets of the results from both Battery Test with the "Charge &
Retest" result and the Diagnostic Charge "Good Battery" result per example of "Print Ticket # B".
7. This is what will occur for GR8 screen when "Replace Battery" results after a Diagnostic Charge attempt:
NOTE:
When the Diagnostic Charge results in "Replace Battery" you may in this circumstance be permitted to claim Op Code 37110A00 for the
Charge Battery attempt and also Op Code 37110R00 for Replace Battery. However you must attach print tickets from both Battery Test with the
"Charge & Retest" result and Diagnostic Charge result showing "Replace Battery" as per example of "Print Ticket # C".
Print Tickets that must be attached to the Repair Order based on Battery Test result and Diagnostic Charge result are shown below, also listed are
the warranty claim types:
WARRANTY CLAIM INFORMATION:

Hyundai Battery Replacement Application Chart:Technical Service Bulletin # 10-FL-013 Date: 101109
Fuel System - Fuel Quality Testing

Group: FUEL SYSTEM
Number: 10-FL-013
Date: NOVEMBER 2010
Subject
TESTING FUEL QUALITY TO DIAGNOSE ENGINE
STARTABILITY / HESITATION / DRIVEABILITY ISSUES
DESCRIPTION:
This bulletin outlines the basic components of the BG Fuel Test Kit and the procedure to test the quality of the fuel during vehicle diagnosis.
Poor fuel quality may lead to cold engine startability issues, hesitation at idle or during acceleration, and/or poor driveability. In addition, prolonged
vehicle operation with poor quality fuel may result in damage to the fuel system and formation of engine deposits.
The BG Fuel Test Kit can be used to determine the following aspects of the fuel:
^ Sediment / Water Contamination Inspection
^ Specific Gravity
^ Alcohol Content
^ ALL MODELS equipped with gasoline engines
PARTS INFORMATION:
The BG Fuel Test Kit (P/N J-48983) is the approved fuel quality testing tool to be used during vehicle diagnosis. This kit is an essential tool that
has been sent to all dealers and is part of the new dealer kit.
Contents of the kit:
- Hydrometers (gasoline / diesel)
- Graduated cylinder (100ml)
- Graduated cylinder (alcohol test)
- Graduated cylinder small stopper
- Graduated cylinder holding fixtures

- Specific gravity vs. temperature reference chart. (shown below / right)
IMPORTANT:
The kit includes TWO (2) different hydrometers.
Do not use the diesel hydrometer with specific gravity range from 0.800 to 0.900.
Use only the gasoline hydrometer with specific gravity range from 0.700 to 0.800 for the correct measurement of the fuel to be tested.
SERVICE PROCEDURE:
1. Prepare the tall graduated cylinder attached to the fixture base.
NOTE:
Be sure that the inside of the cylinder is clean and free of contaminants.
2. Obtain sample fuel from the incident vehicle and fill the graduated cylinder to the 100ml mark.
NOTE:
There are several different methods available to gather a small quantity of fuel for testing. Follow the applicable Shop Manual procedures and
precautions as required to perform any ONE of the following, as feasible.
^ For older MPI fuel systems equipped with a fuel return line, divert the fuel return hose to capture the fuel into a suitable container while
running the engine at idle.
^ For MPI fuel systems that are returnless design, divert the fuel line from the fuel rail to capture the fuel into a container. For additional fuel
amount, briefly prime the fuel pump by cycling the ignition key. (Do not perform this option for GDI engines.)
^ For GDI and MPI systems, lift the vehicle and disconnect the large fuel hose of the fuel filler neck from the fuel tank inlet. Using a long
socket extension, lightly push open the inlet check valve at the inlet of the tank and capture the sample fuel.
^ For GDI and MPI systems, remove the main fuel pump and sender module from the fuel tank to collect the fuel sample through the service
access port, if possible. If equipped, removing the remote fuel sender module may be easier for this task. Avoid fuel spillage.
3. Visually inspect the collected fuel sample for presence of sediment, debris, or water contamination. (Example shown at right. Replace fuel if
contamination is found.)
4. Insert the thermometer into the graduated cylinder and attach the clip to the top rim.
5. Wait a few minutes to allow for the temperature to stabilize, then record the measured temperature of the gasoline sample. Remove the
thermometer afterwards.
6. Insert the gasoline hydrometer with specific gravity range from 0.700 to 0.800 into the graduated cylinder and wait until it stabilizes while
floating in the fuel.
7. Read the number at the liquid line on the side of the hydrometer.
8. Refer to the supplied reference chart to look up the measured temperature and the hydrometer reading to find the corresponding specific gravity.
(Examples shown)
NOTE:
The fuel tanks of vehicles having contaminated fuel or fuel outside the NORMAL specific gravity range should be drained and refilled.
9. Prepare the small graduated cylinder for fuel alcohol content testing.
NOTE:
Be sure that the inside of the cylinder is clean and free of contaminants.
10. With the stopper cap removed, add clean water up to the (A) water fill line.
11. Add fuel from the tall graduated cylinder to the (B) fuel fill line.
12. Insert the stopper cap at the top to seal it and vigorously shake the contents for at least 10 seconds or more.
13. Let the mixture settle for approximately 5~10 minutes.
NOTE:
At this point, any alcohol of the sample will combine with water and begin to separate from the fuel.
14. Read the line where it separates and find the corresponding (D) alcohol % level of the fuel sample.
NOTE:
High alcohol content in the fuel can cause lean codes and other engine startability and driveability conditions.
15. After completing the fuel tests, prepare the Fuel Test Kit for storage.
^ Rinse all pieces with window cleaner and water, then towel dry thoroughly.
^ Store the reference chart behind the protection foam.
^ Arrange all the components so that they are protected by the clamshell storage case.
When necessary, the use of the BG Fuel Test Kit as a part of the normal diagnostic troubleshooting process may be covered under warranty.
However, if the root cause of the condition results from poor fuel quality, then some or all parts and labor expenses may not be covered under
warranty.

Hyundai Sonata L4-1997

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hyundai Sonata L4-1997

Uploaded by

Copyright:

Available Formats

1998 Hyundai Sonata L4-2.0L Copyright © 2011, ALLDATA 10.

VEHICLE IDENTIFICATION NUMBER LOCATION

VEHICLE IDENTIFICATION NUMBER

3. Drive line type

5. Body style & version

10. Plant code

11. Serial number 000001 through 999999

ENGINE IDENTIFICATION PLATE

Engine identification number consists of 11 digits.

4: In line 4 cycle 4 cylinder

6: In line 4 cycle 6 cylinder

3. Engine development order

4. Engine capacity P: 1997cc T : 2972cc V6

6. Engine production sequence number

EMISSION CONTROL DEVICES AND SYSTEMS

MFI/OBD II ........................................................................................................................................................ Computerized Engine Control System

[1] With timing connector grounded.

EMISSION CONTROL DEVICES AND SYSTEMS

MFI/OBD II ........................................................................................................................................................ Computerized Engine Control System

[1] With timing connector grounded.

Special Tools (Part 1 Of 3)

Special Tools (Part 2 Of 3)

Special Tools (Part 3 Of 3)

Special Service Tools

1. Remove the battery.

20. Drain the transaxle oil (or fluid).

8. Crank the engine and read the gauge.

Pressure differential between cylinders: 100 kPa (1.0 kg/cm2, 14 psi)

Spark plug: 20 - 30 Nm (200 - 300 kgs.cm, 14 - 22 ft. lbs.)

1. Disconnect the negative terminal from battery.

1. Install the camshafts on the cylinder head.

L: Intake camshaft. R: Exhaust camshaft

NOTE: Tighten the rocker arms uniformly.

7. Install the camshaft sprockets to the specified torque.

8. Install the rocker cover. Apply sealant as shown.

Bolt length x Diameter:

Piston service size and mark mm (inch)

5. Oversize pistons are available in four sizes.

7. Check for damage and cracks.

NOTE: Size mark is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

4. Bore each of the cylinders to the calculated size.

Piston Pin Removal & Installation Procedures

4. Press the piston pin out of the connecting rod.

Piston Ring End Gap:

1. Install the spacer.

3. Install lower side rail by same procedure as Step 2.

5. Install No. 1 piston ring.

13. Check connecting rod side clearance.

Main Bearings and Connecting Rod Bearings

Oil Clearance Measurement

Standard value: 0.05 - 0.18 mm (0.0020 - 0.0071 inch)

1. Install grooved main bearing (upper bearing) on cylinder block side.

4. Install crankshaft. Apply engine oil to journal and pinch

1. Using a wire brush, clean the valve thoroughly.

Valve stem-to-guide clearance:

Valve Seat Insert

3. Remove the valve stem seals with pliers, and discard.

NOTE: Do not reuse the valve stem seals.

1. Using a wire brush, clean the valve thoroughly.

Valve stem-to-guide clearance:

Valve Seat Insert

5. Clean all cylinder block and cylinder head gasket surfaces.

LASH ADJUSTERS CHECK