Hyundai Coupes/Sedans 1986-1993 Repair Guide

MacPherson Struts

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REMOVAL & INSTALLATION



See Figures 1 through 6



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Fig. Fig. 1: Front suspension components-1986-89 Excel



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Fig. Fig. 2: Front strut assembly-1990-93 Excel and Scoupe



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Fig. Fig. 3: Front strut assembly-Elantra and Sonata



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Fig. Fig. 4: Strut mounting points-all models



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Fig. Fig. 5: Front suspension components-Sonata

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Detach the brake hose from the clip on the strut.
  6.  
  7. Unbolt the strut from the knuckle.
  8.  
  9. Remove the four strut-to-fender apron nuts.
  10.  



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Fig. Fig. 6: Brake line attachment points-Excel

  1. Pull the strut away from the steering knuckle and wheelhouse and out from the car.
  2.  

On Sonata, after the strut is separated from the knuckle, raise the lower control arm with a jack and attach the brake hose, brake line, front speed sensor harness and drive shaft to the steering knuckle with a piece of rope or wire to prevent them from being removed with the strut.

To install:
  1. Before installing the strut, make sure the surface where the strut attaches to the knuckle is clean. This ensures a good connection.
  2.  
  3. Position the strut onto the knuckle and inside fender apron and install the upper and lower attaching hardware.
  4.  
  5. Observe the following torques:

    Strut-to-knuckle bolts-80-94 ft. lbs. (110-130 Nm) for Elantra.
     
    Strut-to-knuckle bolts-54-65 ft. lbs. (74-88 Nm) for 1986-89 Excel.
     
    Strut-to-knuckle bolts-65-76 ft. lbs. (95-105 Nm) for 1990-93 Excel.
     
    Strut-to-knuckle bolts-65-76 ft. lbs. (95-105 Nm) for Sonata.
     
    Strut-to-knuckle bolts-65-76 ft. lbs. (95-105 Nm) for Scoupe.
     
    Strut-to-fender well nuts-25-33 ft. lbs. (35-45 Nm) for Elantra.
     
    Strut-to-fender well nuts-7-11 ft. lbs. (10-15 Nm) for 1986-89 Excel.
     
    Strut-to-fender well nuts-11-14 ft. lbs. (15-20 Nm) for 1990-93 Excel.
     
    Strut-to-fender well nuts-18-25 ft. lbs. (25-34 Nm) for Sonata.
     
    Strut-to-fender well nuts-11-14 ft. lbs. (15-19 Nm) for Scoupe.
     

  6.  
  7. Install the tire and wheel and lower the vehicle.
  8.  

STRUT OVERHAUL



Hyundai does not recommend strut overhaul for late model vehicles. Instead the unit, if determined faulty, should be replaced as an assembly.

1986-89 Excel

See Figures 7 through 11



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Fig. Fig. 7: Spring compressor installed on strut assembly

  1. Remove the strut from the car and clamp in a protected jaw vise.
  2.  
  3. Gently pry the dust cover from the strut insulator with a flat-blade screwdriver.
  4.  

Matchmark the upper end of the coil spring and bearing plate to avoid confusion during reassembly.



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Fig. Fig. 8: Insulator removal

  1. Using a spring compressor, fully compress the spring.
  2.  



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Fig. Fig. 9: Removing the seal

  1. Using the special tools shown, remove the self-locking gland nut.
  2.  



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Fig. Fig. 10: Removing the O-ring

  1. Remove the rubber insulator, support, spring seat rubber bumper and the spring.
  2.  



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Fig. Fig. 11: Pulling the strut cartridge from the housing

  1. Using a brass drift, remove the bearing from the support.
  2.  
  3. Keep the upper mounting parts in order of their removal again to avoid confusion during reassembly.
  4.  
  5. Clean the outside of the strut body, especially around the top. Use the proper size wrench or a pipe wrench to loosen the top strut body nut.
  6.  
  7. Remove the body nut and discard if a new body nut came with the replacement cartridge. If not, save the nut.
  8.  
  9. Use a suitable tool and remove the 0-ring from the top of the housing.
  10.  
  11. Grasp the piston rod and slowly pull the cartridge out of the housing. Remove the cartridge slowly to prevent the oil between the housing and the cartridge from splashing.
  12.  
  13. Pour all of the strut oil into a suitable container, clean the inside of the housing and inspect the cylinder for dents and to insure that all loose parts have been removed from the inside of the strut body.
  14.  
  15. Refill the strut cylinder with one ounce of the original or fresh oil. The oil helps dissipate internal heat during operation and results in a cooler running, longer lasting unit. Do not put too much oil in, otherwise the oil may leak at the body nut after expansion when heated.
  16.  
  17. Insert the replacement cartridge into the strut body. Push the piston rod all of the way down to avoid damage if the wrench slips when install the top nut. Install top body nut, take care not to cross-thread. Tighten the body nut to 100 ft. lbs.
  18.  
  19. Install the coil spring and top end parts, pay attention to the indexing marks you made when disassembling the strut. Make sure that both spring ends align with the groove in the spring seats. Tighten the gland nut to 29-36 ft. lbs.
  20.  
  21. Install the strut on the car.
  22.  

 
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