General Information

General Information

Vehicle Protection. Always cover the fenders, seats and floor before starting work.Preparation of Tools and Measuring Equipment: Before starting work, make sure all necessary tools and measuring equipment are available. Special Service Tools: Use special service tools when required.

Removal of Parts: First identify the cause of the problem, then determine whether removal and disassembly are necessary before starting work.

Disassembly: If the disassembly procedure is so complex that it requires disassembly, all parts must be disassembled in such a way as not to damage their performance or appearance.

1. 1
   Parts Inspection. Each removed part must be carefully inspected for malfunction, deformation, damage, and other problems.

   

2. 2
   Parts Arrangement. All disassembled parts must be neatly arranged for efficient reassembly. Be sure to separate and identify parts to be replaced from those that will be reused.

   

3. 3
   Cleaning of Parts for Reuse. All parts that will be reused must be thoroughly cleaned using an appropriate method.

   

   

4. 4
   Oil Seals
5. 5
   Gaskets
6. 6
   O-rings
7. 7
   Lock Washers
8. 8
   Cotter Pins
9. 9
   Plastic Nuts

   

   Depending on their location.
10. 10
    Apply sealant to gaskets.
11. 11
    Apply oil to the moving parts.
12. 12
    Specified oil or grease must be applied to the specified locations (oil seals, etc.) before assembly.

    

13. 13
    Be sure to disconnect the battery cable from the negative (-) battery terminal.
14. 14
    Never pull on the wires when disconnecting connectors.
15. 15
    Locking connectors will click when securely connected.
16. 16
    Handle sensors and relays carefully. Be careful not to drop them onto other parts.

    

    

17. 17
    Basically, all measurements in this manual are made with a tracking measuring tape.
18. 18
    When using a measuring tape, make sure it is not stretched, twisted, or bent.
19. 19
    Both projected and actual dimensions are used in this manual for measuring dimensions.
20. 20
    Dimensions are measured by projecting measurement points onto the vehicle surface as reference dimensions.
21. 21
    If the length of the guide stopper is adjustable, measure dimensions by extending one of the two probes by the height difference between the two measuring surfaces.

    

22. 22
    These dimensions indicate the actual linear distance between points and are used as reference dimensions when measuring.
23. 23
    First adjust both probes to the same length (A=A') before measuring.

    

    

24. 24
    Check the terminal for tightness.
25. 25
    Check terminals and wires for corrosion from battery electrolyte, etc.
26. 26
    Check terminals and wires for open circuits.
27. 27
    Check wire insulation and coating for damage, cracks, and wear.
28. 28
    Check that the current-carrying parts of the terminals do not contact other metal parts (vehicle body and other components).
29. 29
    Check that there is full continuity between the mounting bolts of the grounded parts and the vehicle body.
30. 30
    Check for correct connections.
31. 31
    Make sure the wiring is clamped to prevent contact with sharp edges of the vehicle body or hot parts (exhaust manifold, pipe, etc.).
32. 32
    Make sure the wiring is securely fastened to provide sufficient clearance from the fan pulley, fan belt, and other rotating or moving parts.
33. 33
    Make sure the wiring has enough slack so it can move between fixed (vehicle body) and moving parts (wiring, engine, etc.).

    

    

34. 34
    Before servicing the electrical system, be sure to turn the ignition switch off and disconnect the negative battery cable.

    

35. 35
    Secure wiring harnesses with clamps so that they do not sag. However, for any harness passing through the engine or other vibrating parts of the vehicle, allow some slack within a range that will not allow engine vibration to cause the harness to contact any surrounding parts, then secure the harness with a clamp.

    

36. 36
    If any section of the wiring harness contacts an edge or corner of a part, wrap that section with tape or similar material to protect it from damage.

    

37. 37
    When installing any parts, take care not to pinch or damage the wiring harness.

    

38. 38
    Never drop relays, sensors, or electrical parts, and do not subject them to strong shocks.

    

39. 39
    Electronic parts used in the computer, relays, etc. are easily damaged by heat. If service operations may cause the temperature to exceed 80 °C, remove the electronic components beforehand.

    

40. 40
    Loose connectors may cause malfunctions. Make sure connectors are always securely connected.

    

41. 41
    When disconnecting a connector, hold only the connector, not the wires.

    

42. 42
    Disconnect connectors with locks by pressing in the direction of the arrows shown in the illustration.

    

43. 43
    Connect connectors with locks by inserting them until they click.

    

44. 44
    When using a circuit tester to check continuity or voltage at a connector terminal, insert the test probe from the wiring harness side. If the connector is a waterproof connector, insert the test probe through the hole in the rubber cap until the probe contacts the terminal, taking care not to damage the wire insulation.

    

45. 45
    To prevent overloading the wiring, take into account the electrical current load of additional equipment when determining the wire size.

    Recommended Wire Size	SAE Sensor No	Allowable Current
    		In Engine Compartment	Other Areas
    0.3 mm²	AWG 22	-	5A
    0.5 mm²	AWG 20	7A	13A
    0.85 mm²	AWG 18	9A	17A
    1.25 mm²	AWG 16	12A	22A
    2.0 mm²	AWG 14	16A	30A
    3.0 mm²	AWG 12	21A	40A
    5.0 mm²	AWG 10	31A	54A

Parts. When replacing parts, use genuine HYUNDAI parts. Replacement. Standard values, such as torque and specified adjustments, must be strictly observed when assembling all parts. After removal, the following parts must always be replaced with new ones. Adjustment. Use gauges and testers to correctly adjust parts to standard values. Electrical System. Rubber Parts and Hoses. Always avoid contact of gasoline or oil with rubber parts or hoses. Body Dimension Measurement. Projected Dimensions. Actual Dimensions Measurement. Measurement Point. Measurements should be taken at the center of the hole. Inspection of Cables and Wires. Fuse Inspection. A blade-type fuse has test taps that allow the fuse to be checked without removing it from the fuse block. The fuse is good if the test lamp lights when one lead is connected to the test taps (one at a time) and the other lead is grounded. (Turn the ignition key so that the fuse circuit is operational.) Electrical System Service. Precautions for Catalytic Converter

1. 1
   Use only unleaded gasoline.
2. 2
   Do not run the engine when the vehicle has been left stationary for a long time. Avoid running the engine at high idle speed for more than 10 minutes and at idle speed for more than 20 minutes.
3. 3
   Do not perform engine compression testing for an extended period. Complete engine compression tests as quickly as possible. Remove the fuel pump relay before performing the compression test.
4. 4
   Do not dispose of a used catalytic converter together with parts contaminated with gasoline or oil.