1991 Hyundai Sonata Service and Repair Manual

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Factory-Grade Data

1991 Hyundai Sonata service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • GL Sedan 4-Door
  • Base Sedan 4-Door
  • GLS Sedan 4-Door

Engines covered

  • 3.0L 2972CC V6 GAS SOHC Naturally Aspirated
  • 2.4L 2351CC l4 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Hyundai Sonata Recalls & Complaints

NHTSA #93V19600029/11/1993Component: SEAT BELTS

THE MOTORIZED SHOULDER BELT CAN TRAVEL SLOWLY OR CHATTER IN THE TRACK AND MAY EVENTUALLY STOP TRACKING AND BECOME INOPERATIVE.

Consequence

SLOWING, CHATTERING, OR FAILURE OF THE MOTORIZED SHOULDERBELT MAY DISCOURAGE USE OF THE RESTRAINT SY

Remedy

DEALERS WILL LUBRICATE THE TRACK ASSEMBLY AND, IF ANY SYSTEMS ARE FOUND INOPERATIVE, THE SYSTEM WILL

TSB #10230904

This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside th

TSB #10189989

This bulletin provides the inspection procedure and repair guidelines for certain vehicles listed below.

TSB #10183963

This bulletin describes the procedure to inspect and identify fluid which may appear around the brake caliper area.

TSB #10183960

This bulletin provides tire vibration service procedures, including how to optimize vehicle vibration performance. For all wheel/tire balance claims, the Tire Balance Data Sheet must be fully completed including imbalance and Road Force Var

TSB #10174808

This bulletin provides information on identifying dealer stock vehicles with either: A Battery SOC alert - low Battery State of Charge (SOC) at or below 50%. A 30 Day alert - vehicle has not started and reported an SOC in 30 days.

TSB #10169370

The Blind Spot Detection (BSD) or Blind-Spot Collision Warning (BCW) is a system that measures the speed of and distance from the following vehicles by using two magnetic wave radar sensors attached in the rear bumper. The BSD/BCW detects v

TSB #10082725

THIS BULLETIN PROVIDES INFORMATION ON COMPONENTS, ATTRIBUTES, AND PRECAUTIONS OF THE 7-SPEED DRY-TYPE DUAL CLUTCH TRANSMISSION (DCT).

TSB #54113

SHOP MANUAL CORRECTION ON CYLINDER HEAD BOLT TORQUE SPECIFICATION. *YC

Showing the 8 most recent of 11 technical service bulletins on file with NHTSA.

19960411Component: VEHICLE SPEED CONTROLCrash reported2 injured

WHILE DRIVING HIGHWAY, ACCELERATOR STUCK; TRIED TO STOP; LOST CONTROL; SPUNOUT 6 TIMES; LURCHED BACKWARDS/FORWARDS ACROSS HIGHWAY; HIT 2 TREES; SPEED 80 MP. *AK

19950213Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTSCrash reported2 injured

BRAKES FAILED, CAUSING ACCIDENT/LOSS OF CONTROL/INJURIES. *AW

20030829Component: AIR BAGSCrash reported1 injured

LTR EXPRESSING HIS DISSATISFACTION WITH THE WAY NHTSA PROCESSED HIS PETITION FOR A HEARING...*MR THE CONSUMER SENT A PETITION FOR DEFECTIVE AIRBAGS. *TS. THE CONSUMER STATED THE AIR BAG RECALL WAS PER

19980403Component: ELECTRICAL SYSTEM:IGNITION:SWITCHFire reported

DRIVER NOTICED SMOKE COMING FROM CAR, TURNED OFF IGNITION, RESTARTED THE CAR AND THE KEY GOT STUCK IN THE IGNITION AND WOULD NOT TURN. A FEW MINUTES LATER, THE CAR CAUGHT ON FIRE IN THE ENGINE COMPART

19970810Component: POWER TRAIN:AUTOMATIC TRANSMISSIONFire reported

COMPLETE TRANSMISSION FAILURE, CAUSING FLUID TO LEAK ALL OVER EXHAUST SYSTEM CREATING SMOKE AND SMALL FIRE.

Showing the 5 most serious of 41 complaints filed with NHTSA.

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