Service Procedure 1992 Sonatas

System Exploded View





1. Open the hood.

2. Remove the radiator gfille. (Review TSB # 92-80-002 May, 1992) (Grille clips may break during removal)

3. Remove RH combination lamp and headlight assemblies.

4. Remove the horn.

5. Loosen the 3 clamps on the oil cooler hoses.

6. Remove the 3 bolts holding the oil cooler and remove the 2 hoses.

7. Install the new (90 mm) yellow marked hose.

NOTE:
Use the new type spring clamps on all hose connections.





8. Install the (520 mm) hose with no marks, to the oil cooler using the new type spring clamp.

9. Re-attach the oil cooler to the radiator support.

10. Lift the car.





11. Install the other end of the (520 mm) hose to the lower radiator tank using the new spring type clamps.

SPEED TIP:
To install the new spring clamps, squeeze clamp ears and insert a 12 mm deep socket into the clamp. Slide a 16 mm socket over the ears of the clamp. This will keep the clamp open. After positioning the clamp in the proper location, the 16 mm socket is pulled off of the clamp. This will make clamp installation faster.





12. Inspect the hose on the LH side of the lower radiator tank. Replace if it is leaking (This hose is not included in the kit).

Note:
It will be necessary to file a separate warranty claim for this procedure.


13. Lower the car.





14. Replace the oil return hose with the red marked hose (430 mm).

15. Replace the oil feed hose with the blue marked hose (270 mm). Use the new style spring clamps.


16. Check to see that all of the newly installed hoses are securely attached and that all hoses are a safe distance from the exhaust manifold.

17. Install the horn, headlight assembly, RH combination lamp and radiator grille assembly.

18. Check the automatic transaxle fluid level.





19. Before closing the hood, place a punch mark over the last character on the identification VIN on the engine compartment bulkhead. This will show that the oil cooler hoses have been changed.