2005 Hyundai Sonata Owners Manual

Be very careful not to touch the radiator hose when adding the engine oil as it may be hot enough to burn you.

CHANGING THE ENGINE OIL AND FILTER G040A01NF-AAT (2.4L) Oil filler cap

(3.3L)

Oil filter

HNF5005

Oil filter

Oil filler cap Oil level dipstick

G040A01NF

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:

DO-IT-YOURSELF MAINTENANCE

(2.4L)

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).

2. Open the hood and remove the engine oil

filler cap.

NOTE: Loosen the oil filter cap by turning it coun- terclockwise to drain well the oil in the oil filter (3.3L only).

HNF5006-1
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.

(3.3L)

WARNING:

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

4. When the oil has stopped draining, replace the drain plug using a new gasket and re- tighten by turning it clockwise.

Oil pan drain plug tightening torque: 25.3 ~ 32.5 lb.ft (3.5 ~ 4.5 kgf.m)

HNF5005-1

G040B01NF

6 DO-IT-YOURSELF MAINTENANCE

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: 8.7 ~ 11.6 lb.ft (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. Remove the engine oil level dipstick. 8. Refill the crankcase with the recommended engine oil. Refer to the specification in chap- ter 9 for engine oil capacity.

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.

PROPOSITION 65 WARNING: Used engine oil may cause irritation or cancer of the skin if left in contact with the skin for prolonged periods of time. Used engine oil contains chemicals that have caused cancer in laboratory animals. Al- ways protect your skin by washing your hands thoroughly with soap and warm water as soon as possible after handling used oil.

CHECKING AND CHANGING THE ENGINE COOLANT

G050A01A-AAT

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.

CAUTION:

Slowly pour the recommended oil into a funnel. Do not overfill to avoid damage to the engine.

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

is leaking from the drain plug or oil filter.

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

G050B01A-AAT Recommended Engine Coolant

G050C01NF-GAT To Check the Coolant Level

G050D01NF-GAT To Change the Engine Coolant

DO-IT-YOURSELF MAINTENANCE

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

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

Antifreeze solution

35% 40% 50% 60%

Water

65% 60% 50% 40%

G050C01NF 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 warm with it at idle . If the level is below the "L" mark, add engine coolant to bring it up to "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.

The engine coolant should be changed at those intervals specified in the vehicle maintenance schedule in Section 5.

CAUTION:

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

o The engine in your vehicle has alumi- num engine parts and must be protected by an ethylene-glycol base coolant to prevent corrosion and freezing. Do not use hard water. Hard water can cause engine damage from corrosion, overheating or freezing.

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

6 DO-IT-YOURSELF MAINTENANCE 10

HNF5008

2. Wrap a thick cloth around the radiator cap and slowly turn the radiator cap counter- clockwise without pressing down on it, until it stops. This relieves any pressure remain- ing in the cooling system. When you are sure that all the pressure has been released, remove the radiator cap by pushing down and turning counterclockwise.

G050D02NF-A 3. 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, and then securely close the drain cock.

4. 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.

5. Slowly fill the radiator with the proper coolant mixture (see the "Recommended Engine Coolant in previous page) until the fluid level stays up in the radiator neck. And pump the radiator hose in order to bleed the air.

G050D01NF 6. Run the engine at idle until the coolant circu- lates. If the cooling fan operates and the coolant starts to circulate, add the coolant to the reservoir.

7. To bleed the air in the cooling system, repeat procedure 6 until the cooling fan operates 3~5 times.

8. Replace the radiator cap and turn it until tightly installed. And then, add coolant to the reservoir until the level is between "L" and "F".

9. Stop the engine and check the coolant level when the engine is cool. The level of the coolant should be the "L" and "F" lines on the reservoir. If the level is below the "L" line, repeat the procedure 4~8 until the level between "L" and "F".

10.Replace the reservoir cap and check to be sure the drain cock and the radiator cap are fully closed and not leaking.

SPARK PLUGS

G060A01NF-AAT

CAUTION:

Recheck after a few days and add the cool- ant if the level is below the "L" 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.

G060A01L Your engine was originally equipped with Iri- dium-tipped spark plugs. Iridium-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 Iridium-tipped spark plugs.

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11

G060B01NF-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

SK16PR-A11
IFR5G-11

Remark

2.4L 3.3L

6 DO-IT-YOURSELF MAINTENANCE 12

G060C01NF-GAT Changing the Spark Plugs

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 engine cover.

NOTE: It is recommended that the spark plugs for 3.3L engines 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.

G060C01NF 3. Remove the cover of the ignition connector

with a flat-head screwdriver.

(2)

(1)

G060C02NF 4. Pull the ignition connector key in the direction

of (1).

5. Press the position (2) of the ignition connec- tor key and detach the ignition connector by pulling it.

(3)

(4)

G060C03NF 6. Remove the mounting bolt (3) of the ignition

coil with a socket wrench.

7. Pull straight up on the ignition coil (4).

DO-IT-YOURSELF MAINTENANCE

13

G060C06NF

G060C05NF 10. To install the new spark plug, guide the socket down over the spark plug, being careful not to damage the ceramic insulator.

! 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.

8. When preparing to remove the spark plug, guide the socket down over the spark plug, being careful not to damage the ceramic insulator.

9. To remove the spark plug, turn the wrench

handle in a counterclockwise direction.

6 DO-IT-YOURSELF MAINTENANCE 14

CHANGING THE AIR CLEANER FILTER

G070A03Y-AAT

CAUTION:

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

o When removing the air cleaner filter, be careful that dust or dirt does not enter the air intake. These may result in dam- age to the air cleaner filter.

G060C04NF 11. Installation is the reverse order of disas-

sembly.

NOTE: Spark plugs should be tightened firmly. (Tightening torque: 18.0 lb.ft (2.5 kgf.m)) 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.

HNF5011
The replacement of the air cleaner filter is performed 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.

WINDSHIELD WIPER BLADES

G080A02A-AAT

G080B01HR-GAT Replacing the Wiper Blades

To replace the wiper blades, raise the wiper to the vertical position.

To remove the wiper blade

DO-IT-YOURSELF MAINTENANCE

15

2. Raise the wiper blade lightly and pull it up.

HHR5049

(1)

HHR5048
1. Push down the wiper blade with the locking clip (1) pressed to detach it from the wiper arm.

G080A01NF-A 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.

CAUTION:

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.

6 DO-IT-YOURSELF MAINTENANCE 16

To install the wiper blade

FILLING THE WASHER RESERVOIR

G090A02NF-AAT (2.4L)

HHR5050

1. Put a new wiper blade onto the wiper arm and lower the wiper blade at the level of the wiper arm as shown in the drawing.

2. Pull up the wiper blade until you hear an audible "click" to engage in the end of the wiper arm.

(3.3L)

HHR5051

NOTE: Do not allow the wiper arm to fall against the windshield.

G090A01NF

G090A02NF The washer fluid reservoir supplies fluid to the windshield washer system.

CHECKING THE TRANSAXLE OIL (MANUAL)

G100A01NF-AAT

DO-IT-YOURSELF MAINTENANCE

17

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.

Drain plug

Filler plug

HNF5010
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/85 (API GL-4) in the manual transaxle.

Manual Transaxle Oil Capacity

The oil capacity of the manual transaxle is 2.0
U.S. quarts (1.9 liters).

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 (4.0 liters).

CAUTION:

o Radiator antifreeze (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.

WARNING:

o Windshield washer fluid agents contain some amounts of alcohol and can be flammable under certain circumstances. Do not allow sparks or flame to contact the washer fluid or the washer fluid reservoir. Damage to the vehicle or its occupants could occur.

o Windshield washer fluid is poisonous to humans and animals. Do not drink wind- shield washer fluid. Serious injury or death could occur.

6 DO-IT-YOURSELF MAINTENANCE 18

G100B02A-AAT To Check the Manual Transaxle Fluid Level

G100B01L Park the car on level ground with the engine off.

CHECKING THE TRANSAXLE FLUID (AUTOMATIC)

G110A01E-AAT Transaxle fluid in the automatic transaxle should be checked at those intervals specified in the vehicle maintenance schedule in Section 5.

NOTE: Automatic transaxle fluid is basically red in color. As driving distance increases, the fluid color turns darkish red gradually. It is a normal condition and you should not judge the need to replace based upon the changing color. You must replace the automatic transaxle fluid in accordance with intervals specified in the vehicle maintenance schedule in section 5.

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

2. Use your finger 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.

G110B05A-AAT Recommended Fluid Your Hyundai automatic transaxle is specially designed to operate with HYUNDAI GENUINE ATF SP III, DIAMOND ATF SP III, SK ATF SP III or other brands meeting the SP III specifica- tion approved by Hyundai Motor Co.. Damage caused by a nonspecified fluid is not covered by your new vehicle limited warranty.

CAUTION:

Use of aftermarket ATF additives may cause damage to the automatic transaxle. Only use HYUNDAI GENUINE ATF SP III, DIAMOND ATF SP III, SK ATF SP III or other brands meeting the SP III specification ap- proved by Hyundai Motor Co.. If you are having your vehicle serviced at a facility other than a Hyundai dealer, verify that the correct ATF is used for your vehicle.

2.4L

3.3L

G110C01NF-AAT Transaxle Fluid Capacity

The fluid capacity of the automatic transaxle is:

8.24 U.S. quarts (7.8 liters)

11.52 U.S. quarts (10.9 liters)

WARNING:

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

DO-IT-YOURSELF MAINTENANCE

19

G110D01NF

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.

G110D02O-AAT To Check the Transaxle Fluid Level

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.

C090F02NF

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.

6 DO-IT-YOURSELF MAINTENANCE 20

CHECKING THE BRAKES

G120A01A-AAT

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.

G120B01A-AAT Checking the Brake Fluid Level

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.

Fluid level should be within "HOT" range

3.

G110D02NF 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.

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.

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.

G120D01A-AAT To Check the Fluid Level

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.

AIR CONDITIONING CARE

DO-IT-YOURSELF MAINTENANCE

21

G120E02A-AAT Adding Brake Fluid

G140A01A-AAT Keeping the Condenser Clean

G140C01A-AAT Lubrication

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.

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.

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.

CAUTION:

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

HNF5013

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.

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.

6 DO-IT-YOURSELF MAINTENANCE CHANGING THE AIR 22
CONDITIONER FILTER

B145A01NF-AAT (For Evaporator and Blower Unit) (If Installed)

The air conditioner filter is located in the right side of the instrument panel. It helps to decrease the amount of pollutants entering the car.

HNF2163-1

1. Remove the cover (1) which is located to the right side of the instrument panel by pulling it.

2. Pull the glove box cylinder (2) to unlock the

glove box retainer.

3. Lower the glove box down completely by pushing both sides of the glove box inward.

HNF2163

HNF2164
4. Remove the air conditioner filter cover by

pressing both side clips.

CAUTION:

Be careful not to damage filter fixing clips.

CHECKING THE FREE-PLAY

DO-IT-YOURSELF MAINTENANCE

23

G150A01A-AAT STEERING WHEEL

G160A01A-GAT CLUTCH PEDAL

1.18 in. (30 mm)

0.24~0.51 in. (6~13 mm)

HNF5018
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.

G160A01HR 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.

HNF2165

5. Replace the air conditioner filter by lifting it. Installation is the reverse order of disassem- 6. bly.

CAUTION:

To prevent pollutants from entering the car, be sure to properly install the air condi- tioner filter.

6 DO-IT-YOURSELF MAINTENANCE 24

G170A01A-AAT BRAKE PEDAL

CHECKING BRAKE PEDAL CLEARANCE

G180A01A-AAT

CHECKING DRIVE BELTS

G190A02NF-GAT

(2.4L)

Power steering Auto tensioner

0.12 ~ 0.31 in. (3 ~ 8 mm)

2.95 in. (75 mm)

Water pump pully

G160A01HR

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.

G180A01L 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.

Generator

COMP

G140D01NF

Generator

Damper pulley

(3.3L)

Water pump pully

Auto tensioner

Power steering

Damper pulley

COMP

G140D02NF

CHECKING AND REPLACING FUSES G200A01A-AAT Replacing a Fusible Link

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25

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.

Drive belts should be checked periodically for proper tension. At the same time, belts should be examined for cracks, wear, fraying or other evidence of deterioration and replaced if neces- sary. When a new belt is replaced, the belt should be located within the pulley of flat idler. Belt routing should also be checked to be sure there is no interference between the belts and other parts of the engine.

NOTE: Drive belt tension is adjusted automatically by the auto tensioner.

HNF4004
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 relay box in the engine compartment for easy inspection.

6 DO-IT-YOURSELF MAINTENANCE 26

G200B01NF-GAT Replacing Accessory Fuse

2. Open the fuse box and examine each fuse. Remove each fuse by pulling it toward you (a small "fuse puller" tool is contained in the relay and fuse box of the engine room to simplify this operation).

3. Be sure to check all other fuses even if you

G200B01NF-A

The fuse box for the lights and other electrical accessories will be found on the left side of the instrument panel. 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.

G200B02NF

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.

Good

Burned out

G200B02L

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.

NOTE: See page 6-39 for the fuse panel descrip- tions.

CHECKING THE BATTERY

G210A01A-AAT

HNF5017

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:

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27

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.

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:

G210B04A-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. Batteries also contain other chemicals known to the state of California to cause cancer. Wash hands after handling.

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.

6 DO-IT-YOURSELF MAINTENANCE 28

WARNING: Always read the following in- structions carefully when han- dling a battery.

Keep lighted cigarettes and all other flames or sparks away from the battery.

Hydrogen, which is a highly com- bustible gas, is always present in battery cells and may explode if ignited.

Keep batteries out of the reach of children because batteries con- tain highly corrosive SULFURIC ACID. Do not allow battery acid to contact your skin, eyes, cloth- ing or paint finish.

If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate medical attention. If possible, continue to apply water with a sponge or cloth until medical attention is received.

WARNING: If electrolyte gets on your skin, thoroughly wash the contacted area. If you feel a pain or a burning sensation, get medical attention immediately.

Wear eye protection when charg- ing or working near a battery. Always provide ventilation when working in an enclosed space.

o When lifting a plastic-cased battery, ex- cessive pressure on the case may cause battery acid to leak, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners.

o Never attempt to charge the battery when

the battery cables are connected.

o The electrical ignition system works with

high voltage. Never touch these components with the engine running or the ignition switched on.

CHECKING ELECTRIC COOLING FANS G220A01A-AAT

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.

G220B01NF-GAT Checking Engine Cooling Fan

The engine cooling fan should come on auto- matically if the engine coolant temperature is high or whenever the air conditioning is in operation.

POWER STEERING FLUID LEVEL

G230A03A-AAT (2.4L)

29

DO-IT-YOURSELF MAINTENANCE

FOR MORE INFORMATION ABOUT YOUR HYUNDAI

G250A01A-AAT If you desire additional information about main- taining and servicing your Hyundai, you may purchase a factory Shop Manual at your Hyundai dealer's parts department. This is the same manual used by dealership technicians and while it is highly technical it can be useful in obtaining a better understanding of your car and how it works.

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.

(3.3L)

G230A01NF

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

It is suggested that you check the power steer- ing hose connections for fluid leakage at those intervals specified in the vehicle maintenance schedule in Section 5. The power steering hoses should be replaced if there is severe surface cracking, pulling, scuffing or worn spots. Deterioration of the hose could cause premature failure.

G230A02NF The power steering fluid level should be checked regularly. To check the power steering fluid level, be sure the engine is "OFF", then check

6 DO-IT-YOURSELF MAINTENANCE 30

HEADLIGHT AIMING ADJUSTMENT

G290A02O-AAT Before performing aiming adjustment, make sure of the following. 1. Keep all tires inflated to the correct pressure. 2. Place the vehicle on level ground and press the front bumper & rear bumper down sev- eral times. Place vehicle at a distance of 118 in. (3m) from the test wall.

3. See that the vehicle is unloaded (except for full levels of coolant, engine oil and fuel, and spare tire, jack, and tools). Have the driver or equivalent weight placed in driver's seat. 4. Clean the headlight lenses and turn on the

headlights (Low beam).

5. Open the hood.

Vertical aiming

G290A01NF-A

6. Draw a vertical line (through the center of each headlight beam pattern) and a horizon- tal line (through the center of each headlight beam pattern) on the aiming screen. And then, draw a parallel line at 0.8 in. (21
mm) under the horizontal line.

7. Adjust each cut-off line of the low beam to the parallel line with a phillips screwdriver - VERTICAL AIMING.

WARNING:

Horizontal aiming should be adjusted by an authorized Hyundai dealer.

G290B01NF-AAT Adjustment After Headlight Assembly Replacement

0.8 in.(21 mm)

Vertical line

Horizontal line

"P"

Cut-off line

Ground line

G260B01GK If the vehicle has had front body repair and the headlight assembly has been replaced, the headlight aiming should be checked using the aiming screen as shown in the illustration. Turn on the headlight switch (Low Beam Position). 1. Adjust headlights so that main axis of light is parallel to the center line of the body and is aligned with point "P" shown in the illustration. 2. Dotted lines in the illustration show the center

of the headlights.

SPECIFICATION: "H" Horizontal center line of headlights from ground : 26.73 in. (679mm)

"W" Distance between each headlight center : 51.41 in. (1,306mm)

"L" Distance between the headlights and the wall that the lights are tested against : 118.11 in. (3,000 mm)

REPLACEMENT OF LIGHT BULBS

G260A01L-GAT Before attempting to replace a light bulb, be sure the switch is turned to the "OFF" position. The next paragraph shows how to reach the light bulbs so they may be changed. Be sure to replace the burned-out bulb with one of the same number and wattage rating. See page 6-38 for the wattage descriptions.

DO-IT-YOURSELF MAINTENANCE

31

G270A01NF-AAT HEADLIGHT, FRONT TURN SIGNAL LIGHT AND FRONT FOG LIGHT

Headlight and Front Turn Signal Light

Headlight (High beam)

Headlight (Low beam)

CAUTION:

o Keep the lights out of contact with pe- troleum products, such as oil, gasoline, etc.

o Be sure to replace the LED type equipped

bulbs with an assembly.

Front Fog Light

Turn signal light (Front position light)

G260A01NF-A

Replacement instructions:

1. Allow the bulb to cool. Wear eye protection. 2. Open the engine hood. 3. Always grasp the bulb by its plastic base,

avoid touching the glass.

6 DO-IT-YOURSELF MAINTENANCE 32

5. Disconnect the power cord from the back of

the headlight.

HNF5023
4. Using a socket wrench of the correct size, remove the headlight assembly mounting bolts.

HNF5025
6. Turn the plastic cover counterclockwise

and remove it.

HNF5024

HNF5026

7. Disconnect the connector from the bulb base in

the back of the headlight.

8. Push the bulb spring to remove the headlight

bulb.

HNF5027
9. Remove the protective cap from the re- placement bulb and install the new bulb by matching the plastic base with the headlight hole. Reattach the bulb spring and recon- nect the connector.

10. Use the protective cap and carton to

promptly dispose of the old bulb. 11. Check for proper headlight aim.

! WARNING:

This halogen bulb contains gas under pres- sure and if impacted could shatter, result- ing in flying fragments. Always wear eye protection when servicing the bulb. Protect the bulb against abrasions or scratches and against liquids when lighted. Turn the bulb on only when installing in a headlight. Replace the headlight if damaged or cracked. Keep the bulb out of the reach of children and dispose of the used bulb with care.

HNF5028

12. To replace the front turn signal light bulb (front position light), remove it from the bulb holder and install the new bulb.

Front Fog Light

NOTE: It is recommended that the front fog light bulb should be replaced by an authorized Hyundai dealer.

G270A03O

DO-IT-YOURSELF MAINTENANCE

33

G270D01NF-AAT REAR COMBINATION LIGHT

Stop/Tail Light, Rear Turn Signal Light, Back-up Light and Rear Side Marker Light

1. Open the trunk lid.

2. Remove the cover on the inside of the rear luggage trim by turning the knob counter- clockwise.

HNF5029

6 DO-IT-YOURSELF MAINTENANCE 34

HNF5030-A

HNF5042

3. To replace the rear combination light (stop/ tail light, rear side marker light and rear turn signal light), remove it from the bulb holder and install the new bulb.

(1) Stop/tail light (2) Rear side marker light (3) Rear turn signal light

4. Loosen the mounting screws of the trunk lid trim with a phillips screwdriver and remove the trunk lid trim.

5. To replace the rear combination light (back- up light and stop/tail light), remove the socket by turning it counterclockwise. Install the new bulb.

6.

G270C01L-AAT LUGGAGE COMPARTMENT LIGHT

1. Open the trunk lid.

HNF5031

2. Remove the luggage compartment light cover on the rear package tray panel with a flat- head screwdriver.

DO-IT-YOURSELF MAINTENANCE

35

G270G01L-AAT INTERIOR LIGHT

Screwdriver

3. Disconnect the power cord.

HNF5032

HNF5034

2. Replace with a new bulb.

HNF5035

1. Remove the plastic cover with a flat-head

screwdriver.

4. Replace with a new bulb.

HTB284

6 DO-IT-YOURSELF MAINTENANCE 36

G270L01L-AAT MAP LIGHT

G270K01L-AAT GLOVE BOX ILLUMINATED LIGHT

1. Open the glove box.

1. Remove the plastic cover with a flat-head

screwdriver.

G270G01NF

2. Replace with a new bulb.

G270G02NF

Screwdriver

2. Remove the glove box illuminated light cover

with a flat-head screwdriver.

HNF5036

DO-IT-YOURSELF MAINTENANCE

37

3. Disconnect the power cord.

HJM5039

4. Replace with a new bulb.

HTB284

6 DO-IT-YOURSELF MAINTENANCE 38

BULB WATTAGES

G280A01NF-AAT

No.

Headlight

Part Name Low beam High beam

Front Turn Signal Light/Front Position Light Map Light Interior Light Front Fog Light Front Side Marker Light Front Door Edge Warning Light

Wattage

Socket Type

55
55
28/8
10
10
27

P x 26d P14,5s BAY15d

w2.1 x 9.5d

sv6-7,6
PGJ13
BAY15d

w2.1 x 4.6d

No. 10
11
12
13
14
15

Part Name

Wattage

Socket Type

Stop / Tail Light High Mounted Rear Stop Light Tail Light Luggage Compartment Light Rear Side Marker Light Rear Turn Signal Light Back-up Light License Plate Light

28/8
16
28/8

27
16

BAY 15d

w2.1 x 9.5d

BAY 15d sv6-7, 6
BAY 15d BAY15s

w2.1 x 9.5d w2.1 x 9.5d

G280A01NF-A

FUSE PANEL DESCRIPTION

G200C01NF-AAT Engine Compartment

DO-IT-YOURSELF MAINTENANCE

39

NOTE: Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time of printing. When you inspect the fuse box on your vehicle, refer to the fuse box label.

HNF4005

6 DO-IT-YOURSELF MAINTENANCE 40

DESCRIPTION

FUSE RATING

FUSIBLE

LINK

FUSE

ABS.1
ABS.2
I/P B+1
RR HTD BLOWER P/WDW IGN.2

ECU RLY I/P B+2
IGN.1
ALT MDPS

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

HORN TAIL ECU IG1
DRL

FR FOG A/CON F/PUMP DIODE ATM STOP

H/LP LO RH

S/ROOF

H/LP WASHER

H/LP HI

ECU

SNSR.3
SNSR.1
SNSR.2

B/UP

IGN COIL ECU (IG1) H/LP LO

ABS

40A 20A 40A 40A 40A 40A 40A 30A 30A 30A 150A 100A 15A 20A 10A 10A 15A 15A 10A 20A

20A 15A 15A 15A 20A 20A 10A 10A 15A 15A 10A 20A 10A 20A 10A

PROTECTED COMPONENTS ABS/ESC control module, Multipurpose check connector ABS/ESC control module, Multipurpose check connector Fuse 23, 24, 30, 31, 32, 33, 34, 35
Defogger relay Blower relay Power window relay, Fuse 16
Start relay, Ignition switch (IG2, START) Engine control unit relay Power connector 1/2, Fuse 21,22
Ignition switch (ACC, IG1) Fusible Iink (ABS. 1, ABS. 2, RR HTD, BLOWER) (Spare) Horn relay Tail light relay PCM (Spare) Siren relay, DRL control module Front fog light relay A/C relay Fuel pump relay (Spare) ATM control relay Stop light relay (Spare) Sunroof control module Headlight washer motor Headlight relay (High) (Spare) Oxygen sensor, Fuel pump relay Mass air flow sensor, Crankshaft/Camshaft position sensor, Oil control valve, SMATRA A/C relay, Cooling fan relay, Injectors Back up light switch, Pulse generator, Vehicle speed sensor Ignition coils, Condenser PCM Headlight relay (Low) ABS/ESC control module, Multipurpose check connector

G200E01NF-AAT Inner Panel

DO-IT-YOURSELF MAINTENANCE

41

HNF4003

6 DO-IT-YOURSELF MAINTENANCE 42

FUSE

FUSE RATING

PROTECTED COMPONENTS

10
11
12
13
14
15
16
17
18
19
20

15A 15A 10A 10A 25A 10A 10A 10A 10A 10A 25A 10A 15A 20A 10A 25A 15A 10A 20A 30A

(Spare) Seat warmer switch BCM(Body Control Module), Sunroof control module, Electronic chrome mirror ESC module, High blower relay, Humidity sensor Cigarette lighter (Spare) Illumination lights, Right : License light, Rear combination light, Headlight, Glove box light Front fog light relay, Left : License light, Rear combination light, Headlight Headlight washer relay, Right headlight leveling actuator DRL control module, Headlight relay, AQS and ambient sensor, Left headlight leveling actuator Wiper and washer A/C control module SRS control module, Passenger's Airbag switch Front accessory socket, Rear power outlet Digital clock, Audio, A/T shift lock control module, Power outside mirror and mirror folding Safety window module (Spare) A/T shift lock control module Power window main switch, Left rear power window switch Power window main switch, Right power window switch

DO-IT-YOURSELF MAINTENANCE

43

FUSE

FUSE RATING

PROTECTED COMPONENTS

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

POWER CONNECTOR. 1
POWER CONNECTOR. 2

20A 20A 10A 30A 10A 10A 10A 15A 10A 15A 15A 15A 15A 30A 10A 10A 15A 15A

Audio amp Door lock/unlock relay Hazard switch, Hazard relay Power seat manual switch(RHD) Instrument cluster Hazard switch BCM(Body Control Module), Instrument cluster, Yaw rate sensor, ESC switch (Spare) Burglar alarm relay (Spare) Rear fog light relay Trunk lid relay, Fuel filler door and trunk lid switch (Spare) Power seat manual switch Sport mode switch, Key solenoid A/C control module, Outside mirror and mirror folding motor Audio BCM(Body Control Module), Digital clock, Instrument cluster, A/C control module, Courtesy lights

EMISSION CONTROL SYSTEMS

Emission Control System ............................................. 7-2
Catalytic Converter ....................................................... 7-3

7 EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS

H010A01NF-AAT Your Hyundai is equipped with an emission control system to meet all emission regulations. There are three emission control systems which are as follows.

(1) Crankcase emission control system (2) Evaporative emission control system (3) Exhaust emission control system

In order to assure the proper function of the emission control systems, it is recommended that you have your car inspected and main- tained by an authorized Hyundai dealer in ac- cordance with the maintenance schedule in this manual.

Caution for the Inspection and Maintenance Test (With Electronic Stability Control (ESC) system)

o To prevent the vehicle from misfiring during dynamometer testing, turn the Electronic Stability Control (ESC) sys- tem off by pressing the ESC switch.

o After dynamometer testing is completed, turn the ESC system back on by pressing the ESC switch again.

H010B01A-AAT 1. Crankcase Emission Control System

The positive crankcase ventilation system is employed to prevent air pollution caused by blow-by gases being emitted from the crank- case. This system supplies fresh filtered air to the crankcase through the air intake hose. Inside the crankcase, the fresh air mixes with blow-by gases, which then pass through the PCV valve into the induction system.

H010C01S-AAT 2. Evaporative Emission Control (Includ- ing ORVR: Onboard Refueling Vapor Recovery) System

The Evaporative Emission Control System is designed to prevent fuel vapors from escaping into the atmosphere. (The ORVR system is designed to allow the vapors from the fuel tank to be loaded into a canister while refueling at the gas station, pre- venting the escape of fuel vapors into the atmosphere.)

Canister

Fuel vapors generated inside the fuel tank are absorbed and stored in the onboard canister. When the engine is running, the fuel vapors absorbed in the canister are drawn into the surge tank through the purge control solenoid valve.

Purge Control Solenoid Valve (PCSV)

The purge control solenoid valve is controlled by the Engine Control Module (ECM); when the engine coolant temperature is low during idling, the PCSV closes so that evaporated fuel is not taken into the engine. After the engine warms- up during ordinary driving, the PCSV opens to introduce evaporated fuel to the engine.

H010D01A-AAT 3. Exhaust Emission Control

System

The Exhaust Emission Control System is a highly effective system which controls exhaust emissions while maintaining good vehicle per- formance.

EMISSION CONTROL SYSTEMS

WARNING:

o Remember that your Hyundai dealer is

your best source of assistance.

o Do not stop your Hyundai over any com- bustible material such as grass, paper, leaves or rags. These materials might contact the hot catalytic converter and a fire might result.

CATALYTIC CONVERTER

H020A01A-AAT

Catalytic Converter

H020A01NF

All Hyundai vehicles are equipped with a mono- lith type three-way catalytic converter to re- duce the carbon monoxide, hydrocarbons and nitrogen oxides contained in the exhaust gas. Exhaust gases passing through the catalytic converter cause it to operate at a very high temperature. The introduction of large amounts of unburned gasoline into the exhaust may cause the catalytic converter to overheat and create a fire hazard. This risk may be reduced by observing the following:

WARNING:

o Use unleaded fuel only. o Maintain the engine in good operating condition. Extremely high catalytic con- verter temperatures can result from im- proper operation of the electrical, igni- tion or multiport electronic fuel injec- tion.

o If your engine stalls, pings, knocks, or is hard to start, have your Hyundai dealer inspect and repair the problem as soon as possible.

o Avoid driving with a very low fuel level. Running out of gasoline may cause the engine to misfire and result in damage to the catalytic converter.

o Avoid idling the engine for periods

longer than 10 minutes.

o The vehicle should not be pushed or pulled to get started. This may cause the catalytic converter to overheat and cre- ate a fire hazard.

o Do not touch the catalytic converter or any other part of the exhaust system while the catalytic converter is hot. Shut off the engine, wait for at least one hour before touching the catalytic converter or any other part of the exhaust system.

CONSUMER INFORMATION, REPORTING

SAFETY DEFECTS & BINDING

ARBITRATION OF WARRANTY CLAIMS

Vehicle Identification Number (VIN) .............................. 8-2
Engine Number ............................................................. 8-2
Tire Information ............................................................. 8-2
Recommended Inflation Pressures ............................... 8-3
Checking Tire Inflation Pressure ................................... 8-4
Tire Sidewall Labeling ................................................... 8-4
Tire Terminology and Definitions ................................... 8-6
All Season Tires ............................................................ 8-8
Summer Tires ............................................................... 8-8
Snow Tires .................................................................... 8-8
Tire Chains.................................................................... 8-8