General Information

General Information

Vehicle Protection. Always cover the fenders, seats and floor before starting work.

Always insert the hood support rod into the hole near the edge of the hood whenever you inspect the engine compartment, to prevent the hood from falling and causing possible injury. Make sure the hood support rod is released before closing the hood. Always check that the hood is securely latched before driving the vehicle.

Preparation of Tools and Measuring Equipment Make sure all necessary tools and measuring equipment are available before starting work. Special Service Tools Use special service tools when required.

Parts Removal Always first identify the cause of the problem, then determine whether removal or disassembly is required before starting work.

Disassembly If the disassembly procedure is complex and requires removing many parts, all parts must be disassembled in a way that does not affect their function or appearance.

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

   

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

   

3. 3
   Cleaning of Parts for Reuse: All parts to 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
    Before assembly, apply specified oil or grease to the designated locations (oil seals, etc.).

    

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
    In general, all measurements in this manual are made with a caliper.
18. 18
    When using a measuring tape, make sure it does not stretch, twist, or bend.
19. 19
    Both projected and actual dimensions are used for measurements in this manual.
20. 20
    These are dimensions measured when the measuring points are projected from the vehicle surface, and serve as reference dimensions for body repair.
21. 21
    If the length of the tracking sensor rods is adjustable, measure it by extending one of the two probes until the height values of the two surfaces are the same.

    

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

    Check the probes and gauge to make sure there is no free play.

    

    

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 the conductive parts of the terminals for contact with other metal parts (vehicle body and other components).
29. 29
    Check the grounded parts to make sure there is full continuity between their mounting bolt(s) and the vehicle body.
30. 30
    Check for correct connections.
31. 31
    Make sure the wiring is secured so it does not contact sharp edges of the vehicle body, etc., or hot parts (exhaust manifold, etc.).
32. 32
    Make sure wiring is secured with sufficient clearance from the fan pulley, fan belt, and other rotating or moving parts.
33. 33
    Make sure the wiring has enough slack so that it can absorb vibration between stationary and moving parts, such as the vehicle body and engine.

    

    

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

    When diagnosing the MFI or ELC system, disconnecting the battery cable will erase any stored diagnostic trouble codes from the computer memory. Therefore, record diagnostic data before disconnecting the battery cable if necessary.

    

35. 35
    Secure the wiring harness with clamps so that there is no slack. However, for any harness that runs near the engine or other vibrating parts of the vehicle, allow some slack within a range that prevents engine vibration from causing the harness to contact any of the surrounding parts, then secure the harness with a tie or clamp.

    

36. 36
    If any section of the wiring harness interferes with the edge of a part or a corner, wrap the section of the harness 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, or subject them to strong impact.

    

39. 39
    Electronic parts used in the computer, relays, etc. are easily damaged by heat. If there is a need for service operations that may cause the temperature to exceed 80 °C, remove the electronic parts before proceeding.

    

40. 40
    Loose connectors cause problems. Make sure that connectors are always securely fastened.

    

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

    

42. 42
    Disconnect the connector with locks by pressing in the direction indicated by the arrows in the illustration.

    

43. 43
    To connect locking connectors, insert the connectors until they click.

    

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

    

45. 45
    To avoid overloading the wiring, take into account the current load of the additional equipment and determine the appropriate wire size.

    Nominal size	SAE Gauge 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. Standard values, such as torque and specified adjustments, must be strictly observed when reassembling all parts. After removal, the following parts must always be replaced with new ones. Adjustment: Use gauges and testers to properly adjust parts to standard values. Electrical System: Rubber Parts and Hoses: Always make sure gasoline does not contact rubber parts or hoses. Measuring Body Dimensions: Dimensions: Measuring Actual Dimensions: Measuring Point: Measurements should be taken at the center of the hole. Inspecting Cables and Wires: Inspecting Fuses: Test terminals are provided for blade-type fuses to check the fuse without removing it from the fuse block. The fuse is good if the test lamp illuminates when connected to the test terminals one terminal at a time and the other lead is grounded. (Turn the ignition key so that the fuse circuit is energized.) Electrical System Service: Precautions for Catalytic Converter

If a large amount of unburned gasoline enters the catalytic converter, it may overheat and create a risk of fire. To prevent this, observe the following precautions and explain them to your customer.

1. 1
   Use only unleaded gasoline.
2. 2
   Do not run the engine when the vehicle has been stationary for a long time. Avoid running the engine at high idle speed for more than 10 minutes or at idle for more than 20 minutes.
3. 3
   Do not measure engine compression for a long period of time. Engine compression test must be performed 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.