1991 Hyundai Sonata Service and Repair Manual
Fitment on this one is exact: the 1991 Hyundai Sonata factory service and repair manual is tied to this model year, engine and trim, so the clearances, settings and tightening sequences you work to are the ones Hyundai published for this car rather than a close figure carried over from an adjacent year.
Engines covered
- 3.0L V6 — SOHC, naturally aspirated, gasoline
- 2.4L inline-four — SOHC, naturally aspirated, gasoline
Body styles covered
- 4-door sedan
Trims covered
- Base
- GL
- GLS
Known issues on the 1991 Sonata. One recall is on federal record for this model year, and it concerns the seat belts: the motorized shoulder belt can travel slowly or chatter in the track and may eventually stop tracking and become inoperative. Slowing, chattering or failure of the motorized shoulder belt may discourage use of the restraint. Owners have filed 41 complaints for the year and Hyundai has issued 10 technical service bulletins. Work on any of it follows the factory diagnostic sequence rather than a generic one.
From a balky motorized shoulder belt to a scheduled service on either the V6 or the four-cylinder, it keeps you on the OEM procedure and the correct specification for your 1991 Sonata.
THE MOTORIZED SHOULDER BELT CAN TRAVEL SLOWLY OR CHATTER IN THE TRACK AND MAY EVENTUALLY STOP TRACKING AND BECOME INOPERATIVE.
SLOWING, CHATTERING, OR FAILURE OF THE MOTORIZED SHOULDERBELT MAY DISCOURAGE USE OF THE RESTRAINT SYSTEM, INCREASING THE RISK OF INJURYIN THE EVENT OF A SUDDEN STOP OR ACCIDENT.
DEALERS WILL LUBRICATE THE TRACK ASSEMBLY AND, IF ANY SYSTEMS ARE FOUND INOPERATIVE, THE SYSTEM WILL BE REPAIRED OR REPLACED, AS REQUIRED.
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
This bulletin provides the inspection procedure and repair guidelines for certain vehicles listed below.
This bulletin describes the procedure to inspect and identify fluid which may appear around the brake caliper area.
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
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.
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
THIS BULLETIN PROVIDES INFORMATION ON COMPONENTS, ATTRIBUTES, AND PRECAUTIONS OF THE 7-SPEED DRY-TYPE DUAL CLUTCH TRANSMISSION (DCT).
SHOP MANUAL CORRECTION ON CYLINDER HEAD BOLT TORQUE SPECIFICATION. *YC
Showing the 8 most recent of 11 technical service bulletins on file with NHTSA.
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
BRAKES FAILED, CAUSING ACCIDENT/LOSS OF CONTROL/INJURIES. *AW
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 PERFORMED ON THE VEHICLE, HOWEVER THE AIR BAG LIGHT CONTINUED TO ILLUMINATE AND THE VEHICLE WAS SERVICED THREE TIMES TO CORRECT THE PROBLEM. THE CONSUMER'S WIFE WAS INVOLVED IN A ONE CAR ACCIDENT IN WHICH THE AIR BAGS FAILED TO DEPLOY. *JB
IGNITION STUCK IN START POSITION, CAUSING STARTER TO BURN OUT/CATCH FIRE.
COMPLETE TRANSMISSION FAILURE, CAUSING FLUID TO LEAK ALL OVER EXHAUST SYSTEM CREATING SMOKE AND SMALL FIRE.
CAR CAUGHT FIRE AT A COMPLETE STOP. PLEASE DESCRIBE. *AK
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 COMPARTMENT. OWNER WAS ABLE TO PUT OUT FIRE, BUT THE KEY WOULD NOT COME OUT OF THE IGNITION. THE VEHCLE IS BEING REPAIRED. *AK
ALTENATOR AND STARTER ARE DEFECTIVE, RESULTING IN ENGINE FIRE. *AK
TRANSMISSION COOLANT LINE DEVELOPED A LEAK AND SPRAYED FLUID ONTO THE EXHAUST SYSTEM, CAUSING A FIRE. TT
THE DRIVER'S SIDE SEAT BELT RETRACTOR STOPPED WORKING, CONSUMER HAD IT LUBRICATED UNDER RECALL, BUT STILL NOT WORKING, RECEIVED RECALL LETTER # 93V196000 . PLEASE DESCRIBE. *AK
DRIVER'S SEAT BELT FAILS OCCASIONALLY.
HOLE IN MUFFLER REPAIRED/MUFFLER REPLACED.
PASSENGER'S FRONT SEAT CANNOT BE ADJUSTED.
TRANSMISSION SERVICED.
CHECK ENGINE LIGHT COMES ON.
Showing the 15 most serious of 45 complaints filed with NHTSA.
