2003 Hyundai Sonata Owners Manual

and mild soap or car-washing solution.

o Do not expose the bumpers to high tem- peratures. For example, if you have your car repainted, do not leave the bumpers on the car if the car is going to be placed in a high- temperature paint booth.

To Clean the Vinyl Upholstery To clean the vinyl upholstery, first remove loose dirt and dust with a vacuum cleaner. Then apply a solution of mild soap or detergent and water using a clean sponge or soft cloth. Allow this to stay on the surface to loosen the dirt, then wipe with a clean damp sponge or cloth. If all the dirt stains are not removed, repeat this procedure until the upholstery is clean. Do not use gaso- line, solvent, paint thinner or other strong clean- ers.

E040B01A-AAT To Clean the Leather Upholstery (If installed)

In the normal course of use, leather upholstered surfaces will, like any material, pick-up dust and dirt. This dust and dirt must be cleaned off or it may work into the surface of the leather, caus- ing damage.

Fine leather needs care, and should be cleaned when necessary. Washing leather thoroughly with soap and water will keep your leather lustrous, beautiful and ensure you have many years of wear.

CORROSION PREVENTION AND APPEARANCE CARE 4- 5

Take a piece of cheese cloth and using any mild soap and lukewarm water, work up a good lather. Thoroughly wash the leather. Wipe clean with a slightly damp cloth and dry with soft cloth. Do this as often as the leather becomes soiled.

During tanning operations, sufficient oils are incorporated through processing that none need be applied during the life of the leather. Oil applied to the finished surface will in no way help the leather and may do more harm than good. Varnishes and furniture polishes should never be used under any conditions.

E040C01A-AAT Cleaning the Carpets

Use a foam-type carpet cleaner. Cleaners of this type are available in aerosol cans in liquid form or powder. Read the instructions and follow them exactly. Using a vacuum cleaner with the appropriate attachment, remove as much dirt from the carpets as possible. Apply the foam following the manufacturer's direc- tions, then rub in overlapping circles. Do not add water. These cleaners work best when the carpet is kept as dry as possible.

E040D01A-AAT Cleaning the Seat Belts

To clean the seat belts, use a cloth or sponge with mild soap or detergent and warm water. Do not use strong detergents, dye, bleach or abra- sive materials on the seat belts as this may weaken the fabric. While cleaning the belts, inspect them for ex- cessive wear, cuts, fraying or other signs of damage and replace them if necessary.

E040E01A-AAT Cleaning the Windows

You may use any household window cleaner on the windows. However, when cleaning the in- side of the rear window be careful not to damage the rear window defroster wiring.

E050A01A-AAT Any Questions?

If you have any questions about the care of your car, consult your Hyundai dealer.

5. VEHICLE MAINTENANCE

REQUIREMENTS

Maintenance intervals ......................................................................5-2
Scheduled maintenance ...................................................................5-4
Maintenance under severe usage conditions ...................................5-6
Explanation of scheduled maintenance items ..................................5-7

5- 2 VEHICLE MAINTENANCE REQUIREMENTS

F010A01A-AAT MAINTENANCE INTERVALS

F010C01A-AAT Specified Scheduled Procedures

F010D01A-AAT General Checks

Service Requirements To ensure that you receive the greatest number of miles of satisfying operation from your Hyundai, certain maintenance procedures must be per- formed. Although careful design and engineer- ing have reduced these to a minimum, those that are required are of the utmost importance. It is your responsibility to have these mainte- nance procedures performed to comply with the terms of the warranties covering your new Hyundai. The Owner's Handbook supplied with your new vehicle provides further information about these warranties.

F010B01A-AAT Maintenance Requirements

The maintenance required for your Hyundai can be divided into three main areas:

o Specified scheduled procedures o General checks o Do-it-yourself maintenance

These are the procedures such as inspections, adjustments and replacements that are listed in the maintenance charts starting on page 5-4. These procedures must be performed at the intervals shown in the maintenance schedule to assure that your warranty remains in effect. Although it is strongly recommended that they be performed by the trained technicians at your Hyundai dealer, these procedures may be per- formed at any qualified service facility. It is suggested that genuine Hyundai service parts be used for any required repairs or re- placements. Other parts of equivalent quality such as engine oil, engine coolant, manual or auto transaxle oil, brake fluid and so on which are not supplied by Hyundai Motor Company or its distributor may be used without affecting your warranty coverage but you should always be sure these are equivalent to the quality of the original Hyundai parts. Your Owner's Hand- book provides further information about your warranty coverage.

These are the regular checks you should per- form when you drive your Hyundai or you fill the fuel tank. A list of these items will be found on page 6-4.

F010E01A-AAT Do-It-Yourself Maintenance

If you are mechanically inclined, own a few tools that are required and want to take the time to do so, you can inspect and service a number of items. For more information about doing it your- self, see Section 6.

F010F01A-AAT A Few Tips

o Whenever you have your Hyundai serviced, keep copies of the service records in your glovebox. This will help ensure that you can document that the required procedures have been performed to keep your warranties in effect. This is especially important when service is not performed by an authorized Hyundai dealer.

o If you choose to do your own maintenance and repairs, you may find it helpful to have an official Hyundai Shop Manual. A copy of this publication may be purchased at your Hyundai dealer's parts department.

F020A02Y-AAT SCHEDULED MAINTENANCE REQUIREMENTS

VEHICLE MAINTENANCE REQUIREMENTS 5- 3

o Inspection should be performed any time a malfunction is experienced or suspected. o Receipts for all emission control system services should be retained to demonstrate compliance with conditions of the emissions system warranty.

o After 120 months or 150,000 miles (240,000
km), continue to follow the prescribed main- tenance intervals.

o For severe usage maintenance require-

ments, see page 5-6 of this section.

F020A02Y-AAT SCHEDULED MAINTENANCE REQUIREMENTS

o Inspection should be performed any time a malfunction is experienced or suspected. o Receipts for all emission control system services should be retained to demonstrate compliance with conditions of the emissions system warranty.

o After 120 months or 150,000 miles (240,000
km), continue to follow the prescribed main- tenance intervals.

o For severe usage maintenance require-

ments, see page 5-6 of this section.

5- 4 VEHICLE MAINTENANCE REQUIREMENTS

F030A01A-AAT SCHEDULED MAINTENANCE

The following maintenance services must be performed to ensure good emission control and performance. Keep receipts for all vehicle emission services to protect your warranty. Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.

F030B02Y-AAT R :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.

No.

DESCRIPTION

KILOMETERS X 1000

MILES X 1000

MONTHS

7.5

12

15

24

12

22.5

30

37.5

45

52.5

36

18

48

24

60

30

72

36

84

42

60

96

48

67.5

75

82.5

90

97.5

105

112.5

120

127.5

135

142.5

150

108

120

132

144

156

168

180

192

204

216

228

240

54

60

66

72

78

84

90

96

102

108

114

120

EMISSION CONTROL ITEMS

ENGINE OIL AND FILTER

FUEL FILTER

FUEL LINES, FUEL HOSES AND CONNECTIONS

VACUUM AND CRANKCASE VENTILATION HOSES

VAPOR HOSE AND FUEL FILLER CAP

AIR CLEANER FILTER

SPARK PLUGS (PLATINUM COATED)

VEHICLE MAINTENANCE REQUIREMENTS 5- 5

F030C07Y-AAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary

No.

DESCRIPTION

MILES X 1000
KILOMETERS X 1000
MONTHS

GENERAL ITEMS DRIVE BELT

2.4DOHC (ALT, W/PUMP) 2.7V6 ( ALT, P/STR'G, A/CON)

COOLANT TIMING BELT MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID AND FILTER BRAKE FLUID BRAKE HOSES AND LINES REAR BRAKE DRUMS/LININGS, PARKING BRAKE BRAKE PADS, CALIPERS AND ROTORS EXHAUST PIPE AND MUFFLER SUSPENSION MOUNTING BOLTS STEERING GEAR BOX, LINKAGE & BOOTS/LOWER ARM BALL JOINT, UPPER ARM BALL JOINT POWER STEERING PUMP AND HOSES DRIVESHAFTS AND BOOTS AIR CONDITIONING REFRIGERANT AIR FILTER (For Evaporator and Blower unit)

10
11
12

13
14
15
16

7.5
12

15
24
12

22.5
36
18

30
48
24

37.5
60
30

45
72
36

52.5
84
42

60
96
48

R*¹

67.5
108
54

75
120
60

82.5
132
66

90
144
72

97.5
156
78

105
168
84

112.5
180
90

See Note *2

120
192
96

R*¹

127.5
204
102

135
216
108

142.5
228
114

150
240
120

Note : *1. FOR CALIFORNIA, THIS MAINTENANCE IS RECOMMENDED, BUT NOT REQUIRED. *2. FOR EVERY 12 MONTHS OR 12,000 MILES (20,000 KM), WHICHEVER OCCURS FIRST : "R"

5- 6 VEHICLE MAINTENANCE REQUIREMENTS

F040A04Y-AAT MAINTENANCE UNDER SEVERE USAGE CONDITIONS

The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals.

R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary

MAINTENANCE ITEM

MAINTENANCE

OPERATION

MAINTENANCE

INTERVALS

DRIVING

CONDITION

ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS BRAKE PADS, CALIPERS AND ROTORS REAR BRAKE DRUMS/LININGS, PARKING BRAKE STEERING GEAR BOX, LINKAGE & BOOTS/ LOWER ARM BALL JOINT, UPPER ARM BALL JOINT DRIVESHAFTS AND BOOTS MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID AND FILTER AIR FILTER (FOR EVAP. AND BLOWER UNIT)

VERY 3,000 MILES (4,800 KM) OR 3 MONTHS MORE FREQUENTLY MORE FREQUENTLY MORE FREQUENTLY

A, B, C, F, H C, E B, H C, D, G, H

MORE FREQUENTLY

MORE FREQUENTLY

C, D, G, H

C, D, E, F, G

EVERY 7,500 MILES (12,000 KM) OR 6 MONTHS EVERY 60,000 MILES (96,000 KM) EVERY 30,000 MILES (48,000 KM) MORE FREQUENTLY

C, E, F A, C, D, E, F, G, H, I, J A, C, E, F, G, H, I C, E

SEVERE DRIVING CONDITIONS A - Repeated short distance driving B - Extensive idling C - Driving in dusty, rough roads D - Driving in areas using salt or other corrosive materials or in

very cold weather

E - Driving in sandy areas

F - More than 50% driving in heavy city traffic during hot weather

above 90°F (32°C)

G - Driving in mountainous areas H - Towing a trailer J - Driving over 100 mph

- Driving for patrol car, taxi or commercial car and vehicle towing

F060A01A-AAT EXPLANATION OF SCHEDULED MAIN- TENANCE ITEMS

F060D01A-AAT o Fuel Lines, Fuel Hoses and Connec- tions

F060M01A-AAT o Engine Oil and Filter

The engine oil and filter should be changed at the intervals specified in the maintenance sched- ule. If the car is being driven in severe condi- tions, more frequent oil and filter changes are required.

F060C01A-AAT o Fuel Filter

A clogged filter can limit the speed at which the vehicle may be driven, damage the emission system and cause hard starting. If an exces- sive amount of foreign matter accumulates in the fuel tank, the filter may require replacement more frequently. After installing a new filter, run the engine for several minutes, and check for leaks at the connections. Fuel filters should be installed by trained technicians.

F060B02A-AAT o Drive Belts

Inspect all drive belts for evidence of cuts, cracks, excessive wear or oil saturation and replace if necessary. Drive belts should be checked periodically for proper tension and adjusted as necessary.

Check the fuel lines, fuel hoses and connec- tions for leakage and damage. Have a trained technician replace any damaged or leaking parts immediately.

F060F01A-AAT o Vacuum, Crankcase

Ventilation Hoses

Inspect the surface of hoses for evidence of heat and/or mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions, and excessive swelling indicate deterioration. Particular attention should be paid to examine those hose surfaces nearest to high heat sources, such as the exhaust manifold. Inspect the hose routing to assure that the hoses do not come in contact with any heat source, sharp edges or moving component which might cause heat damage or mechanical wear. Inspect all hose connections, such as clamps and couplings, to make sure they are secure, and that no leaks are present. Hoses should be replaced immediately if there is any evidence of deterioration or damage.

VEHICLE MAINTENANCE REQUIREMENTS 5- 7

F060G01A-AAT o Vapor Hose and Fuel Filler Cap

The vapor hose and fuel filler cap should be inspected at those intervals specified in the maintenance schedule. Make sure that a new vapor hose or fuel filler cap is correctly re- placed.

F060H01A-AAT o Air cleaner filter

A Genuine Hyundai air cleaner filter is recom- mended when filter is replaced.

F060J01A-AAT o Spark plugs

Make sure to install new spark plugs of the correct heat range.

F060E01A-AAT o Timing belt

Inspect all parts related to the timing belt for damage and deformation. Replace any dam- aged parts immediately.

F070C01A-AAT o Coolant

The coolant should be changed at the intervals specified in the maintenance schedule.

5- 8 VEHICLE MAINTENANCE REQUIREMENTS

F070D01A-AAT o Manual transaxle oil

F070G02A-AAT o Brake Fluid

F070K01A-AAT o Exhaust Pipe and Muffler

Inspect the manual transaxle oil according to the maintenance schedule.

NOTE: If the oil level is low, check for possible leaks before adding oil. Do not overfill.

F070E04A-AAT o Automatic Transaxle Fluid and Filter

The fluid level should be in the "HOT" range of the dipstick, after the engine and transaxle are at normal operating temperature. Check the automatic transaxle fluid level with the engine running and the transaxle in neutral, with the parking brake properly applied. Use Genuine Hyundai ATF or DIAMOND ATF SP-III or SK ATF SP-III when adding or changing fluid.

F070F01A-AAT o Brake Hoses and Lines

Visually check for proper installation, chafing, cracks, deterioration and any leakage. Replace any deteriorated or damaged parts immedi- ately.

Check brake fluid level in the brake fluid reser- voir. The level should be between "MIN" and "MAX" marks on the side of the reservoir. Use only hydraulic brake fluid conforming to DOT 3
or DOT 4.

Visually inspect the exhaust pipes, muffler and hangers for cracks, deterioration, or damage. Start the engine and listen carefully for any exhaust gas leakage. Tighten connections or replace parts as necessary.

F070H01A-AAT o Rear Brake Drums and Linings/

Parking Brake

Check the rear brake drums and linings for scoring, burning, leaking fluid, broken parts, and excessive wear. Inspect the parking brake system including the parking brake lever and cables. For detailed service procedures, refer to the Shop Manual.

F070J01A-AAT o Brake Pads, Calipers and Rotors

Check the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage.

F070L01A-AAT o Suspension Mounting Bolts

Check the suspension connections for loose- ness or damage. Retighten to the specified torque.

F070M01Y-AAT o Steering Gear Box, Linkage & Boots/ Lower Arm Ball Joint, Upper Arm Ball Joint

With the vehicle stopped and engine off, check for excessive free-play in the steering wheel. Check the linkage for bends or damage. Check the dust boots and ball joints for deterioration, cracks, or damage. Replace any damaged parts.

VEHICLE MAINTENANCE REQUIREMENTS 5- 9

F070N01A-AAT o Power Steering Pump, Belt and Hoses

Check the power steering pump and hoses for leakage and damage. Replace any damaged or leaking parts immediately. Inspect the power steering belt for evidence of cuts, cracks, ex- cessive wear, oiliness and proper tension. Replace or adjust it if necessary.

F070P01A-AAT o Driveshafts and Boots

Check the drive shafts, boots and clamps for cracks, deterioration, or damage. Replace any damaged parts and, if necessary, repack the grease.

F070Q01A-AAT o Air Conditioning Refrigerant

Check the air conditioning lines and connec- tions for leakage and damage. Check air con- ditioning performance according to the relevant shop manual if necessary.

6. Do-It-Yourself Maintenance

Engine compartment ........................................................................6-2
General checks ................................................................................6-4
Checking the engine oil ....................................................................6-5
Changing the oil and filter .................................................................6-6
Checking and changing the engine coolant......................................6-7
Spark plugs ......................................................................................6-9
Changing the air cleaner filter .........................................................6-11
Checking the transaxle oil (Manual) ...............................................6-12
Checking the transaxle fluid (Automatic) .......................................6-13
Checking the brakes ......................................................................6-14
Air conditioning care .......................................................................6-15
Checking drive belts ......................................................................6-18
Checking and replacing fuses ........................................................6-18
Replacement of bulbs ....................................................................6-21
Junction Box description ................................................................6-29

6- 2 DO-IT-YOURSELF MAINTENANCE

G010A02Y-GAT ENGINE COMPARTMENT (2.4 DOHC)

2 3

9 10 11 12

13

14

HEF-064

1. Engine oil filler cap 2. Brake Booster 3. Brake fluid reservoir 4. Clutch fluid reservoir (If installed) 5. Under hood junction box

6. Windshield washer fluid reservoir 7. Power steering fluid reservoir 8. Engine oil level dipstick 9. Engine cover

10.Automatic transaxle fluid level dipstick

(If installed) 11.Radiator cap 12.Air cleaner 13.Coolant reservoir cap 14.Battery

G010B03Y-AAT ENGINE COMPARTMENT (2.7 V6 Delta)

DO-IT-YOURSELF MAINTENANCE 6- 3

1 2 3

9 10

1112 13

G010B04Y

1. Air cleaner 2. Brake fluid reservoir 3. Brake booster 4. Windshield washer fluid reservoir 5. Power steering fluid reservoir

6. Engine oil level dipstick 7. Engine cover 8. Engine oil filler cap 9. Automatic transaxle fluid level dipstick

(If installed)

10.Radiator cap 11.Battery 12.Coolant reservoir cap 13.Under hood junction box

6- 4 DO-IT-YOURSELF MAINTENANCE

G020A01A-AAT GENERAL CHECKS

G020B01A-AAT Vehicle Exterior

G020C01A-AAT Vehicle Interior

Engine Compartment The following should be checked regularly:

o Engine oil level and condition o Transaxle fluid level and condition o Brake fluid level o Clutch fluid level o Engine coolant level o Windshield washer fluid level o Accessory drive belt condition o Engine Coolant hose condition o Fluid leaks (on or below components) o Power steering fluid level o Battery condition

The following should be checked monthly:

o Overall appearance and condition o Air filter condition o Wheel condition and wheel nut torque o Exhaust system condition o Light condition and operation o Windshield glass condition o Wiper blade condition o Paint condition and body corrosion o Fluid leaks o Door and hood lock condition o Tire pressure and condition (including spare

tire)

The following should be checked each time when the vehicle is driven:

o Lights operation o Windshield wiper operation o Horn operation o Defroster, heating system operation (and air

conditioning, if installed)

o Steering operation and condition o Mirror condition and operation o Turn signal operation o Accelerator pedal operation o Brake operation, including parking brake o Manual transaxle operation, including clutch

operation

o Automatic transaxle operation, including

"Park" mechanism operation

o Seat control condition and operation o Seat belt condition and operation o Sunvisor operation

If you notice anything that does not operate correctly or appears to be functioning incor- rectly, inspect it carefully and seek assistance from your Hyundai dealer if service is needed.

G030A01A-AAT CHECKING THE ENGINE OIL

G030B01A-AAT Recommended Oil

G030C02A-AAT To Check the Oil Level

DO-IT-YOURSELF MAINTENANCE 6- 5

Engine oil is essential to the performance and service of the engine. It is suggested that you check the oil level at least once a week in normal use and more often if you are on a trip or driving in severe conditions.

SH, SG or SG/CD (API) multi-grade and fuel efficient oil is recommended.

G030A02A

G030C01Y Before checking the oil, warm up the engine to the normal operating temperature and be sure your car is parked on level ground. Turn the engine off.

Wait five minutes, then remove the dipstick, wipe it off, fully reinsert the dipstick and withdraw it again. Then note the highest level the oil has reached on the dipstick. It should be between the upper ("F") and lower ("L") range.

6- 6 DO-IT-YOURSELF MAINTENANCE

G030D01A-AAT Adding Oil

G040A02A-AAT CHANGING THE OIL AND FILTER

DOHC

V6

DOHC

V6

The engine oil and filter should be changed at those intervals specified in the maintenance schedule in Section 5. If the car is being driven in severe conditions, more frequent oil and filter changes are required.

The procedure for changing the oil and filter is as follows:

G030D01Y If the oil level is close to or below the "L" mark, add oil until it reaches the "F" mark. To add oil:

HSM394

1. Remove the oil filler cap by turning it counter-

2. Add oil, then check the level again. Do not

clockwise.

overfill.

3. Replace the cap by turning it clockwise.

1. Park the car on level ground and set the parking brake. Start the engine and let it warm up until the needle on the coolant temperature gauge moves above the lowest mark. Turn the engine off and place the gear selector lever in "P" (automatic) or reverse gear (manual transaxle). Set the parking brake.

2. Open the hood and remove the engine oil

filler cap.

3. Slide underneath the car and loosen the drain plug by turning it counterclockwise with a wrench of the proper size. Be sure that a drain pan is in position to catch the oil as it drains out, then remove the drain plug.

The distance between the "F" and "L" marks is equal to about 1 quart of oil.

WARNING:

Be very careful when draining the engine oil as it may be hot enough to burn you!

DO-IT-YOURSELF MAINTENANCE 6- 7

G050A01A-AAT CHECKING AND CHANGING THE EN- GINE COOLANT

WARNING:

Do not remove the radiator cap when the engine is hot. When the engine is hot, the engine coolant is under pressure and may erupt through the opening if the cap is removed. You could be seriously burned if you do not observe this precaution. Do not remove the radiator cap until the radiator is cool to the touch.

NOTE: Always dispose of used engine oil in an environmentally acceptable manner. It is suggested that it be placed in a sealed container and taken to a service station for reclamation. Do not pour the oil on the ground or put it into the household trash.

WARNING:

Used motor oil may cause irritation or can- cer of the skin if left in contact with the skin for prolonged periods of time. Wash your hands thoroughly with soap and warm water as soon as possible after handling used oil.

4. When the oil has stopped draining, replace the drain plug using a new washer and retighten by turning it clockwise.

Tightening torque is: 3.5 ~ 4.5 kgf.m

5. Remove the oil filter by turning it counter- clockwise with a oil filter wrench of the proper size. A certain amount of oil will come out when you remove the filter. So be sure to have your drain pan in place underneath it. Install a new oil filter in accordance with the instructions on the carton or on the filter itself. Do not over-tighten.

6.

Tightening torque is: 1.2 ~ 1.6 kgf.m

Be sure that the mounting surface on the engine is clean and that the old gasket is removed completely. Lubricate the new gasket on the filter with clean engine oil before installation.

7. Refill the crankcase with the recommended engine oil. Refer to the specification in chap- ter 9 for engine oil capacity.

8. Start the engine and check to be sure no oil

is leaking from the drain plug or oil filter.

9. Shut off the engine and recheck the oil level.

6- 8 DO-IT-YOURSELF MAINTENANCE

G050B01A-AAT Recommended Engine Coolant

G050B01Y Use a high quality ethylene-glycol coolant in a 50/50 mix with water. The engine coolant should be compatible with aluminum engine parts. Additional corrosion inhibitors or additives should not be used. The cooling system must be maintained with the correct concentration and type of engine coolant to prevent freezing and corrosion. Never allow the concentration of antifreeze to exceed the 60% level or go below the 35% level, or damage to the cooling system may result. For proper concentration when adding or replacing the engine coolant, refer to the following table.

Ambient

Engine Coolant concentration

temperature

°C ( °F) -15 (5) -25 (-13) -35 (-31) -45 (-49)

Antifreeze solution

35% 40% 50% 60%

Water

65% 60% 50% 40%

G050C01A-AAT To Check the Coolant Level The coolant level can be seen on the side of the plastic coolant reservoir. The level of the cool- ant should be between the "L" and "F" lines on the reservoir when the engine is cool. If the level is below the "L" mark, add engine coolant to bring it up between "L" and "F". If the level is low, inspect for coolant leaks and recheck the fluid level frequently. If the level drops again, visit your Hyundai dealer for an inspection and diagnosis of the reason.

G050D02A-AAT To Change the Engine Coolant The engine coolant should be changed at those intervals specified in the vehicle maintenance schedule in Section 5.

CAUTION: Engine coolant can damage the finish of your car. If you spill engine coolant on the car, wash it off thoroughly with clean water.

1. Park the car on level ground, set the park- ing brake and remove the radiator cap when cool.

2. Be sure your drain receptacle is in place. Open the drain cock on the radiator. Allow all the engine coolant to drain from the cooling system, then securely close the drain cock. 3. Check Section 9 for the capacity of the cooling system in your car. Then, following the manufacturer's directions on the engine coolant container, add the appropriate quan- tity of coolant to the radiator.

4. Turn the radiator cap counterclockwise with- out pressing down on it, until it stops. This relieves any pressure remaining in the cool- ing system. And remove the radiator cap by pushing down and turning counterclock- wise. Now fill the radiator with clean demineralized or distilled water. Continue to add clean demineralized or distilled water in small quan- tities until the fluid level stays up in the radiator neck.

5. Start the engine, top off the radiator with water and then add coolant to the reservoir until the level is between "L" and "F".

6. Replace the radiator and reservoir caps and check to be sure the drain cocks are fully closed and not leaking.

WARNING:

The cooling fan is controlled by engine coolant temperature and may sometimes operate even when the engine is not run- ning. Use extreme caution when working near the blades of the coolant fan so that you are not injured by a rotating fan blade. As the engine coolant temperature de- creases, the fan will automatically shut off. This is a normal condition.

G060A02Y-AAT SPARK PLUGS

DOHC

V6

0.1~1.1 mm

0.1~1.1 mm

HSM392
Your engine was originally equipped with plati- num-tipped spark plugs. Platinum-tipped spark plugs will last longer than conventional type spark plugs and can be identified by blue lines on the ceramic shell.

NOTE: Do not clean or regap platinum-tipped spark plugs.

DO-IT-YOURSELF MAINTENANCE 6- 9

G060B04Y-AAT Replacing the Spark Plugs The spark plugs should be changed at the intervals specified in the vehicle maintenance schedule in Section 5 or whenever engine performance indicates they should be changed. Symptoms that suggest poor spark plug perfor- mance include engine misfiring under load, loss of fuel economy, poor acceleration, etc. When spark plugs are replaced, always use spark plugs recommended by Hyundai. The use of other spark plugs can result in loss of perfor- mance, radio interference or engine damage.

NOTE: When replacing the spark plugs, always use the genuine parts recommended.

Recommended Spark Plugs:

Type

Remark

RN10PYP4 (CHAMPION) PGR5C-11 (NGK) RC10PYB4 (CHAMPION) PFR5N-11 (NGK)

For 2.4L only

For 2.7L only

6- 10 DO-IT-YOURSELF MAINTENANCE

G060C04Y-AAT Changing the Spark Plugs

3. To remove the spark plug cable, pull straight up on the insulated connector, not the cable. Pulling on the cable may damage the carbon core conductor.

6. To install the new spark plug, guide the socket down over the spark plug, being careful not to damage the ceramic insulator.

G060C01O You will find it easier to change spark plugs if the engine is cold. Always change one spark plug at a time. This helps avoid getting the wires mixed up.

1. Remove the center (2.4 L) cover on the

engine rocker cover.

NOTE: It is recommended that the spark plugs (For 2.7L Engines) should be changed by an authorized Hyundai dealer.

2. Using a clean cloth, remove any dirt that has accumulated around the base of the spark plug so it cannot fall into the cylinder when the spark plug is removed.

G060C02O

WARNING:

It is recommended that the engine be cool or cold when changing the spark plugs. If the engine is hot, you could burn yourself on the insulated connector, the spark plug or the engine itself.

4. When preparing to remove the old spark plug, guide the socket down over the spark plug, being careful not to damage the ce- ramic insulator.

5. To remove the old spark plug, turn the wrench handle in a counterclockwise direc- tion.

G060C03O

NOTE: Spark plugs should be tightened to speci- fication. Over-tightening can damage the threads in the aluminum cylinder head. Also, leaving them too loose can cause the spark plug to get very hot and possibly result in damage to the engine.

7. Replace the cable by pushing the insulated connector directly down onto the electrode. Check to be sure it has snapped into place and can’t fall off.

G070A03Y-AAT CHANGING THE AIR CLEANER FILTER

G080A02A-AAT WINDSHIELD WIPER BLADES

G090A01A-AAT FILLING THE WASHER RESERVOIR

DO-IT-YOURSELF MAINTENANCE 6- 11

G070A01YT The replacement of air cleaner filter is per- formed in the following manner.

1. Unsnap the clips around the cover. 2. When this is done, the cover can be lifted off, the old filter removed and the new filter put in its place.

Genuine Hyundai replacement parts are rec- ommended.

CAUTION:

Operating your vehicle without using a proper air cleaner filter in place can result in excessive engine wear.

HEF119

The wiper blades should be carefully inspected from time to time and cleaned to remove accu- mulations of road film or other debris. To clean the wiper blades and arms, use a clean sponge or cloth with a mild soap or detergent and water. If the wipers continue to streak or smear the glass, replace them with genuine Hyundai re- placement parts or their equivalent.

NOTE: o Do not operate the wipers on dry glass. This can result in more rapid wear of the wiper blades and may scratch the glass. o Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc.

G230A03YT The washer fluid reservoir supplies fluid to the windshield washer system. A good quality washer fluid should be used to fill the washer reservoir. The fluid level should be checked more frequently during bad weather or whenever the washer system is in more fre- quent use. The capacity of the washer reservoir is 3.2 U.S. quarts (3.0 Liters).

CAUTION:

o Radiator anti-freeze (engine coolant) should not be used in the washer system because it will damage the car’s finish. o The washer lever should not be pulled and the washer should not be operated if the washer reservoir is empty. This can damage the washer fluid pump.

6- 12 DO-IT-YOURSELF MAINTENANCE

G100A03Y-AAT CHECKING THE TRANSAXLE OIL (MANUAL)

Filler plug

Drain plug

G100A03Y Transaxle lubricant in the manual transaxle should be checked at those intervals specified in the vehicle maintenance schedule in Section 5.

Recommended Oil Use only HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4) or equivalent in the manual transaxle.

Manual Transaxle Oil Capacity The oil capacity of the manual transaxle is 2.2
U.S. quarts (2.1 liters).

WARNING:

It is always better to check the transaxle oil level when the engine is cool or cold. If the engine is hot, you should exercise great caution to avoid burning yourself on hot engine or exhaust parts.

2. Use your finger or suitable tool to feel inside the hole. The oil level should be at its bottom edge. If it is not, check for leaks before adding oil. To refill the transaxle or bring the oil level up,add oil slowly until it reaches the proper level. Do not overfill.

3. Replace the plug and washer, screw it in with your fingers and then tighten securely with the wrench.

G100B02A-AAT To Check the Manual Transaxle Fluid Level

G110A01A-AAT CHECKING THE TRANSAXLE FLUID (AUTOMATIC)

Transaxle fluid in the automatic transaxle should be checked at those intervals specified in the vehicle maintenance schedule in Section 5.

G110B03A-AAT Recommended Fluid

Your Hyundai automatic transaxle is specially designed to operate with HYUNDAI GENUINE ATF or DIAMOND ATF SP-III or SK ATF SP-III. Damage caused by a nonspecified fluid is not covered by your new vehicle limited warranty.

SSA6100B Park the car on level ground with the engine off.

1. Using a wrench of the correct size, loosen the oil filler plug by turning it counterclock- wise and remove it with your fingers.

G110C01Y-AAT Transaxle Fluid Capacity The fluid capacity of the automatic transaxle is 8.2 U.S. quarts.

G110D02L-AAT To Check the Transaxle Fluid Level

DOHC

V6

DO-IT-YOURSELF MAINTENANCE 6- 13

WARNING:

The transaxle fluid level should be checked when the engine is at normal operating temperature. This means that the engine, radiator, exhaust system etc., are very hot so you should exercise great care not to burn yourself during this procedure.

C090A01Y Park the car on level ground with the parking brake engaged. When the transaxle fluid level is checked, the transaxle fluid should be at normal operating temperature and the engine idling.

G110D02Y-1

While the engine is idling, apply the brakes and move the gear selector lever from "P" to each of its other positions — "R", "N", "D" — and then return to "N" or "P". With the engine still idling:

1. Open the hood, being careful to keep hands, long hair and clothing clear of any moving parts.

2. Remove the transaxle dipstick, wipe it clean, reinsert the dipstick as far as it will go, then remove it again. Now check the fluid level on the dipstick. It should be in the "HOT" range on the dipstick. If the transaxle fluid level is low, use a funnel to add transaxle fluid through the dipstick tube until the level reaches the "HOT" range. Do not overfill.

3.

6- 14 DO-IT-YOURSELF MAINTENANCE

G120A01A-AAT CHECKING THE BRAKES

G120D01A-AAT To Check the Fluid Level

Fluid level should be within "HOT" range

CAUTION:

Because brakes are essential to the safe operation of the car, it is suggested that they be checked and inspected by your Hyundai dealer. The brakes should be checked and inspected for wear at those intervals specified in the vehicle mainte- nance schedule in Section 5.

The fluid level in the brake fluid reservoir should be checked periodically. The level should be between the "MIN" and "MAX" marks on the side of the reservoir. If the level is at or below the "MIN" mark, carefully add fluid to bring it up to "MAX". Do not overfill.

G120E02A-AAT Adding Brake Fluid

HKSOM120

G120B01A-AAT Checking the Brake Fluid Level

WARNING:

The cooling fan is controlled by engine coolant temperature and may sometimes operate even when the engine is not run- ning. Use extreme caution when working near the blades of the cooling fan, so that you are not injured by a rotating fan blade. As the engine coolant temperature de- creases, the fan will automatically shut off. This is a normal condition.

WARNING:

Use caution when handling brake fluid. It can damage your vision if it gets into your eyes. It will also damage your vehicle's paint if spilled on it and not removed imme- diately.

G120C02A-AAT Recommended Brake Fluid

Use only hydraulic brake fluid conforming to DOT 3 or DOT 4 specifications in your braking system. Follow the instructions printed on the container.

HEF-234

!

WARNING:

Handle brake fluid carefully. It can damage your vision if it gets into your eyes. Use only DOT 3 or DOT 4 specification fluid from a sealed container. Do not allow the fluid can or reservoir to remain open any longer than required. This will prevent entry of dirt and moisture which can damage the brake sys- tem and cause improper operation.

G130A01A-AAT CHECKING THE CLUTCH FLUID To Check the Clutch Fluid

DO-IT-YOURSELF MAINTENANCE 6- 15

G130B02A-AAT To Replace the Fluid

Recommended brake fluid conforming to DOT 3 or DOT 4 specification should be used. The reservoir cap must be fully tightened to avoid contamination from foreign matter or moisture.

NOTE: Do not allow any other liquids to contami- nate the brake fluid. Seal damage will result.

To add brake fluid, first wipe away any dirt then unscrew the fluid reservoir cap. Slowly pour the recommended fluid into the reservoir. Do not overfill. Carefully replace the cap on the reser- voir and tighten.

G130A01Y The clutch fluid level in the master cylinder should be checked when performing other un- der hood services. The system should be checked for leakage at the same time. Check to make certain that the clutch fluid level is always between the "MAX" and "MIN" level markings on the fluid reservoir. Fill as required. Fluid loss indicates a leak in the clutch system which should be inspected and repaired imme- diately. Consult your Hyundai dealer.

WARNING:

Use caution when handling brake fluid. It can damage your vision if you get it in your eyes. It will also damage your vehicle's paint if spilled on it and not removed imme- diately.

G140A01A-AAT AIR CONDITIONING CARE

Keeping the Condenser Clean The air conditioning condenser (and engine radiator) should be checked periodically for accumulation of dirt, dead insects, leaves, etc. These can interfere with maximum cooling ef- ficiency. When removing such accumulations, brush or hose them away carefully to avoid bending the cooling fans.

6- 16 DO-IT-YOURSELF MAINTENANCE

G140B01A-AAT Checking the Air Conditioning Opera- tion

1. Start the engine and let it run at a fast idle for several minutes with the air conditioning set at the maximum cold setting. If the air coming out of the in-dash vents is not cold, have the air conditioning system inspected by your Hyundai dealer.

2.

G140D01A-AAT Checking the Compressor Drive Belt

DOHC

V6

G150A01A-AAT CHECKING STEERING WHEEL FREE-PLAY

Auto tensioner

CAUTION:

Running the air conditioning system for extended periods of time with a low refrig- erant level may damage the compressor.

G140C01A-AAT Lubrication

To lubricate the compressor and the seals in the system, the air conditioning should be run for at least 10 minutes each week. This is particularly important during cool weather when the air conditioning system is not otherwise in use.

COMP

Eng.pulley

0.315 in.

Eng.pulley

COMP

HSM396
When the air conditioning is being used regu- larly, the compressor drive belt tension should be checked at least once a month with the engine turned off. To check the drive belt tension, press down on the belt halfway between the engine crankshaft and compressor pulleys. Pressing with your finger, you should not be able to deflect this belt anymore than 1/3 of an inch. If you have the instruments to check it, with a force of 22 lb. (98N), the deflection should be 0.315 inches (approx 8.0 mm). If the belt is too loose, have it adjusted by your Hyundai dealer.

Maximum 1.18 in. (30 mm)

G150A01Y To check the steering wheel free-play, stop the car with the wheels pointed straight ahead and gently move the steering wheel back and forth. Use very light finger pressure and be sensitive to changes in resistance that mark the limits of the free-play. If the free-play is greater than specified, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.

G160A01A-AAT CHECKING CLUTCH PEDAL FREE-PLAY

G170A02A-AAT CHECKING BRAKE PEDAL FREE-PLAY

G180A01A-AAT CHECKING BRAKE PEDAL CLEARANCE

DO-IT-YOURSELF MAINTENANCE 6- 17

0.24~0.51 in. (6~13 mm)

0.12~0.31 in. (3~8 mm)

2.95 in. (75 mm)

G160A01E With the engine off, press lightly on the clutch pedal until you feel a change in resistance. This is the clutch pedal free-play. The free-play should be within the limits specified in the illus- tration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.

HXGS508

G180A01L

With the engine off, press down on the brake pedal several times to reduce the vacuum in the brake booster. Then, using your hand, press down slowly on the brake pedal until you feel a change in resistance. This is the brake pedal free-play. The free-play should be within the limits speci- fied in the illustration above. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.

You need a helper to check the brake pedal clearance. With the engine running, have your helper press down on the brake pedal several times and then hold it down with a force of about 110 lbs (50 kg, 490 N). The brake pedal clear- ance is the distance from the top surface of the brake pedal to the asphalt sheeting under the floor mat. If the brake pedal clearance is not within the limits specified in the illustration, have it in- spected by your Hyundai dealer and adjusted or repaired if necessary.

6- 18 DO-IT-YOURSELF MAINTENANCE

G190A01A-AAT CHECKING DRIVE BELTS

V6

DOHC

Power steering

Auto tensioner

Eng.coolant

Power steering

0.30~0.48in. 0.24~0.35in.

G200A01Y-GAT CHECKING AND REPLACING FUSES Replacing a Fusible Link

CAUTION:

When replacing a fusible link, never use anything but a new fusible link with the same or lower amperage rating. Never use a piece of wire or a higher-rated fusible link. This could result in serious damage and create a fire hazard.

Generator

COMP

Generator

COMP

Eng.pulley

Eng.pulley

HSM396

Drive belts should be checked periodically for proper tension and adjusted if necessary. At the same time, belts should be examined for cracks, wear, fraying or other evidence of deterioration and replaced if necessary. Belt routing should also be checked to be sure there is no interference between the belts and other parts of the engine. After a belt is replaced, the new belt should be adjusted again after two or three weeks to eliminate slack resulting from initial stretching after use.

Bad

Good

G200B01Y-GAT Replacing Accessory Fuse

G200A01L A fusible link will melt if the electrical circuits from the battery are ever overloaded, thus prevent- ing damage to the entire wiring harness. (This could be caused by a short in the system drawing too much current.) If this ever happens, have a Hyundai dealer determine the cause, repair the system and replace the fusible link. The fusible links are located in a under hood junction box for easy inspection.

G200B01Y The instrument panel junction box for the lights and other electrical accessories will be found low on the dashboard on the driver’s side. Inside the box you will find a list showing the circuits protected by each fuse.

If any of your car’s lights or other electrical accessories stop working, a blown fuse could be the reason. If the fuse has burned out, you will see that the metal strip inside the fuse has burned through. If you suspect a blown fuse, follow this procedure:

1. Turn off the ignition and all other switches. 2. Open the instrument panel junction box and examine each fuse. Remove each fuse by pulling it toward you (a small "fuse puller" tool is contained in the fuse box to simplify this operation).

Fuse Puller

HXGS416
3. Be sure to check all other fuses even if you find one that appears to have burned out. 4. Replace the blown fuse by pressing a new fuse of the same rating into place. The fuse should be a snug fit. If it is not, have the fuse clip repaired or replaced by a Hyundai dealer.

If you do not have a spare fuse, you may be able to borrow a fuse of the same or lower rating from an accessory you can tempo- rarily get along without (the radio or cigarette lighter, for example). Always remember to replace the borrowed fuse.

DO-IT-YOURSELF MAINTENANCE 6- 19

NOTE: See page 6-29 for the junction box descrip- tions.

G210A01A-AAT CHECKING THE BATTERY

WARNING:

Batteries can be dangerous! When working with batteries, carefully observe the follow- ing precautions to avoid serious injuries.

The fluid in the battery contains a strong solution of sulfuric acid, which is poisonous and highly corrosive. Be careful not to spill it on yourself or the car. If you do spill battery fluid on yourself, immediately do the following:

o If battery fluid is on your skin, flush the affected areas with water for at least 15
minutes and then seek medical assistance. o If battery fluid is in your eyes, rinse out your eyes with water and get medical assistance as soon as possible. While you are being driven to get medical assistance, continue to rinse your eyes by using a sponge or soft cloth saturated with water.

o If you swallow battery fluid, drink a large quantity of water or milk followed by milk of magnesia, eat a raw egg or drink vegetable oil. Get medical assistance as soon as possible.

Good

Burned out

G200B03Y

CAUTION:

A burned-out fuse indicates that there is a problem in the electrical circuit. If you re- place a fuse and it blows as soon as the accessory is turned on, the problem is serious and should be referred to a Hyundai dealer for diagnosis and repair. Never re- place a fuse with anything except a fuse with the same or a lower amperage rating. A higher capacity fuse could cause damage and create a fire hazard.

6- 20 DO-IT-YOURSELF MAINTENANCE

While batteries are being charged (either by a battery charger or by the vehicle's generator), they produce explosive gases. Always ob- serve these warnings to prevent injuries from occurring: o Charge batteries only in a well ventilated

o Do not permit flames, sparks or smoking in

area.

the area.

o Keep children away from the area.

G210B02A-AAT Checking the Battery

Keep the battery clean. Any evidence of corro- sion around the battery posts or terminals should be removed using a solution of house- hold baking soda and warm water. After the battery terminals are dry, cover them with a light coating of grease.

PROPOSITION 65 WARNING: Battery posts, terminals, and related acces- sories contain lead and lead compounds, chemicals known to the state of California to cause cancer and reproductive harm. Wash hands after handling.

G220A01A-AAT CHECKING ELECTRIC COOLING FANS

G230A03A-AAT POWER STEERING FLUID LEVEL

WARNING:

The cooling fan is controlled by engine coolant temperature and may sometimes operate even when the engine is not run- ning. Use extreme caution when working near the blades of the coolant fan, so that you are not injured by a rotating fan blade. As the engine coolant temperature de- creases the fan will automatically shut off. This is a normal condition.

G220B01A-AAT Checking Engine Cooling Fan

The engine cooling fan should come on auto- matically if the engine coolant temperature is high.

G220C01A-AAT Checking Condenser Cooling Fan

The condenser coolant fan should come on automatically whenever the air conditioning is in operation.

G230A03Y The power steering fluid level should be checked regularly. To check the power steering fluid level, be sure the engine is "OFF", then check to make certain that the power steering fluid level is between the "MAX" and "MIN" level markings on the fluid reservoir.

NOTE: Grinding noise from the power steering pump may be heard immediately after the engine is started in extremely cold condi- tions (below - 4°F). If the noise stops during warm up, there is no abnormal function in the system. It is due to a power steering fluid characteristic in extremely cold condi- tions.

Recommended Fluid Use PSF-3 type fluid

NOTE: Do not start the engine when the power steering oil reservoir is empty.

G240A01A-AAT POWER STEERING HOSES