fuel cap Hyundai Sonata 2004 Owner's Manual

1- 2 FEATURES OF YOUR HYUNDAI
CAUTION:Your Hyundai's New Vehicle Limited War-
ranty may not cover damage to the fuel
system and any performance problems that
are caused by the use of fuels containing
methanol or fuels containing MTBE (Methyl
Tertiary Butyl Ether) over 15.0% vol. (Oxy-
gen Content 2.7% weight.)B010B01A-AATWhat About Gasohol?
Gasohol (a mixture of 90% unleaded gasoline
and 10% ethanol or grain alcohol) may be used
in your Hyundai. However, if your engine devel-
ops driveability problems, the use of 100%
unleaded gasoline is recommended. Fuels with
unspecified quantities of alcohol, or alcohols
other than ethanol, should not be used.
B010A02A-AATFUEL RECOMMENDATIONS
Use Unleaded Gasoline
Unleaded gasoline with a Pump Octane
Rating of 87 (Research Octane Number 91)
or higher must be used in your Hyundai.
If leaded gasoline is used, it will cause the
catalytic converter to become ineffective and
the emission control system to malfunction.
This can also result in increased maintenance
expense.
To avoid accidental use of leaded fuel, the larger
nozzle used with leaded gasoline at service
stations cannot be inserted into the fuel tank
opening of your Hyundai.
B010C01A-AAT
Use of MTBE
Hyundai recommends that fuels containing
MTBE (Methyl Tertiary Butyl Ether) over 15.0%
vol. (Oxygen Content 2.7% weight) should not
be used in your Hyundai.
Fuel containing MTBE over 15.0% vol. (Oxygen
Content 2.7% weight) may reduce vehicle per-
formance and produce vapor lock or hard
starting.
B010D01A-AATDo Not Use Methanol
Fuels containing methanol (wood alcohol) should
not be used in your Hyundai. This type of fuel
can reduce vehicle performance and damage
components of the fuel system.
B010E01A-AATGasolines for Cleaner AirTo help contribute to cleaner air, Hyundai rec-
ommends that you use gasolines treated with
detergent additives, which help prevent deposit
formation in the engine. These gasolines will
help the engine run cleaner and the Emission
Control System performance.
!
CAUTION:o Do not "TOP-OFF" after the first nozzle
shut off when refueling.
o The fuel cap must be tightened at least
3 clicks, otherwise " " light may
illuminate.
B010A03Y-1
UNLEADED
FUEL ONLY
!

1- 38 FEATURES OF YOUR HYUNDAI
!
B290A01A-AATENGINE COOLANT TEMPERATURE
GAUGE
WARNING:
Never remove the radiator cap when the
engine is hot. The engine coolant is under
pressure and could erupt and cause severe
burns. Wait until the engine is cool before
adding coolant to the reservoir.
The needle on the engine coolant temperature
gauge should stay in the normal range. If it
moves across the dial to "H" (Hot), pull over and
stop as soon as possible and turn off the engine.
Then open the hood and check the coolant
reservoir level and the water pump drive belt. If
you suspect cooling system trouble, have your
cooling system checked by a Hyundai dealer as
soon as possible.
B300A01A-AATSPEEDOMETER
Your Hyundai's speedometer is calibrated in
miles per hour (on the outer scale) and kilome-
ters per hour (on the inner scale).HEF-009HEF-008B
B280A01A-AATFUEL GAUGE
The needle on the gauge indicates the approxi-
mate fuel level in the fuel tank. The fuel capacity
is given in Section 9.
HEF-010 B270A01A-AAT
BRAKE PAD WEAR WARNING SOUND
The front disc brake pads have wear indicators
that should make a high-pitched squealing or
scraping noise when new pads are needed. The
sound may come and go or be heard all the time
when the vehicle is moving. It may also be heard
when the brake pedal is pushed down firmly.
Excessive rotor damage will result if the worn
pads are not replaced. See your Hyundai dealer
immediately.

1- 58 FEATURES OF YOUR HYUNDAI
!
B560A02Y-AATREMOTE FUEL-FILLER LID RELEASE
The fuel-filler lid may be opened from inside the
vehicle by pushing up on the fuel-filler lid opener
located on the driver side door.
NOTE:If the fuel-filler lid will not open because ice
has formed around it, tap lightly or push on
the lid to break the ice and release the lid. Do
not pry on the lid. If necessary, spray around
the lid with an approved de-icer fluid (do
not use radiator anti-freeze) or move the
vehicle to a warm place and allow the ice to
melt.
B550A02Y-AATHIGH-MOUNTED REAR STOP LIGHT
In addition to the lower-mounted rear stoplights
on either side of the car, the high mounted rear
stoplight in the center of the rear window also
lights when the brakes are applied.WARNING:o Gasoline vapors are dangerous. Before
refueling, always stop the engine and
never allow sparks or open flames near
the filler area. If you need to replace the
filler cap, use a genuine Hyundai re-
placement part.
o If you open the fuel filler cap during high
ambient temperatures, a slight "pres-
sure sound" may be heard. This is nor-
mal and not a cause for concern.
Whenever you open the fuel filler cap,
turn it slowly.
o Make sure the fuel filler cap is replaced
and securely seated after fueling. Failure
to replace or fully seat the fuel filler cap
will result in fuel vapors escaping into
the atmosphere and the check engine
(MIL) indicator illuminating.
B550A03Y
HEF-132AB560A02Y
Fuel Cap Holder

FEATURES OF YOUR HYUNDAI 1- 59
B570A01L-GATHOOD RELEASE
1. Pull the release knob to unlatch the hood.
2. Press the safety catch lever up and lift the
hood.
3. Raise the hood by hand.
When closing the hood, slowly close the hood
and make sure it locks into place.
o Do not "TOP-OFF" after the first nozzle
shut off when refueling.
o The fuel cap must be tightened at least
3 clicks, otherwise " " light will
illuminate.
1MS104008 B560B01L-GAT
Manual Fuel Filler Lid Release
If the fuel filler lid cannot be opened using the
remote opener, a manual opener handle is
located inside the trunk on the left side. Open the
fuel filler lid by pulling on this handle as shown
in the illustration.
HXG115
WARNING:o Always double check to be sure that the
hood is firmly latched before driving
away. If it is not latched, the hood could
open while the vehicle is being driven,
causing a total loss of visibility, which
might result in an accident.
o Do not move the vehicle with the hood
in the raised position, as vision is ob-
structed and the hood could fall or be
damaged.
HEF-134A
!

5- 4 VEHICLE MAINTENANCE REQUIREMENTS
F030A01A-AATSCHEDULED 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.
DESCRIPTION
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) No.
1
2
3
4
5
6
7MILES X 1000
KILOMETERS X 1000
MONTHS7.5
12
6
R15
24
12
R22.5
36
18
R30
48
24
R
I
I
R37.5
60
30
R45
72
36
R52.5
84
42
R
R
I60
96
48
R
I
I
R
R67.5
108
54
R75
120
60
R82.5
132
66
R90
144
72
R
I
I
R97.5
156
78
R105
168
84
R
R
I112.5
180
90
R120
192
96
R
I
I
R
R127.5
204
102
R135
216
108
R142.5
228
114
R150
240
120
R
I
I
R
F030B02Y-AATR :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.

VEHICLE MAINTENANCE REQUIREMENTS 5- 7
F060G01A-AATo 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.
F060D01A-AATo Fuel Lines, Fuel Hoses and Connec-
tions
Check the fuel lines, fuel hoses and connec-
tions for leakage and damage. Have a trained
technician replace any damaged or leaking
parts immediately.
F060A01A-AATEXPLANATION OF SCHEDULED MAIN-
TENANCE ITEMS
F060B02A-AATo 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.
F060M01A-AATo 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-AATo 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.
F060F01A-AATo 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.
F070C01A-AATo Coolant
The coolant should be changed at the intervals
specified in the maintenance schedule.
F060E01A-AATo Timing belt
Inspect all parts related to the timing belt for
damage and deformation. Replace any dam-
aged parts immediately.
F060J01A-AAT
o Spark plugs
Make sure to install new spark plugs of the
correct heat range.
F060H01A-AATo Air cleaner filter
A Genuine Hyundai air cleaner filter is recom-
mended when filter is replaced.

DO-IT-YOURSELF MAINTENANCE 6- 9
!
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.G060A02Y-AATSPARK PLUGS
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.
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.
HSM392G060B04Y-AAT
Replacing the Spark PlugsThe 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
RN10PYP4 (CHAMPION)
PGR5C-11 (NGK)
RC10PYB4 (CHAMPION)
PFR5N-11 (NGK)Remark
For 2.4L only
For 2.7L only
DOHC V6
1.0~1.1 mm 1.0~1.1 mm

7- 2 EMISSION CONTROL SYSTEMS
H010E01Y-AATEGR System (If installed)
This system helps reduce nitrogen oxides by
recirculating a part of the exhaust gas into the
engine, thereby reducing cylinder combustion
temperature, which results in lower output of
oxides of nitrogen.
H010D01A-AAT3. Exhaust Emission Control System
The Exhaust Emission Control System is a
highly effective system which controls exhaust
emissions while maintaining good vehicle
performace.
H010B01A-AAT1. 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 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
and into the induction system.
H010A01L-AATEMISSION CONTROL SYSTEM
Your Hyundai is equipped with an emission
control system to meet all requirements of the
U.S. Environmental Protection Agency or Cali-
fornia Air Resources Board.
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 Inspection and Maintenance
Test (2.7 V6 Vehicle with Traction Control
System)
o To prevent the vehicle from misfiring
during dynamometer testing, discon-
nect the ABS connector located on the
left side of the engine compartment.
o For more information, see shop manual
(BR-67, Wheel Speed Sensor)
H010C02S-AAT
2. Evaporative Emission Control
(Including 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.

9- 2 VEHICLE SPECIFICATIONS
J060A01Y-AAT
FUEL SYSTEM
J050A02Y-AATBRAKE
J040A03Y-AATELECTRICAL
J030A05Y-AATTIRE
J020A01Y-AAT
POWER STEERING
J010A03Y-AATMEASUREMENT
186.9 in. (4747 mm)
71.7 in. (1820 mm)
55.9 in. (1422 mm)
106.3 in. (2700 mm)
60.6 in. (1540 mm)
60.2 in. (1530 mm) Overall length
Overall width
Overall height (unladen)
Wheel base
Wheel tread
Front
Rear
Type
Wheel free play
Rack stroke
Oil pump typeRack and pinion
0 ~ 1.18 in. (0 ~ 30 mm)
5.75 in. (146 mm)
5.6 in. (142 mm)
Vane type
Tire pressure
30 (207)
60 (414)Tire
Standard
Spare
Item
Battery
Generator2.4L
MF 60AH (12V)2.7L (V6)
MF 68 AH (12V)
95A (13.5 V)
Dual hydraulic with brake booster
Solid disc
Disc type (with ABS)
Drum type (without ABS)
Cable operated on rear wheel Type
Front brake type
Rear brake type
Parking brake
17.2 us.gal (14.3 lmp.gal, 65 liter)
psi (kpa)
Size
P205/65R15
P205/60R16
T125/70D15, T125/70R15Fuel tank capacity 15" tire
16" tire

VEHICLE SPECIFICATIONS 9- 3
J070A03Y-AATENGINE
ITEMS
Engine Type
Bore x Stroke. in. (mm)
Displacement. cc
Firing order
Spark plugType
Gap
Oil pan capacity us.qt. (lmp.qt., liter)
Oil filter capacity us.qt. (lmp.qt., liter)
Idle speed (rpm)
Ignition timing (Base)
Oil grade (API)2.4L (DOHC)
4-Cyl., In-line DOHC
3.41x 3.94 (86.5 x 100)
2,351
1 - 3 - 4 - 2
CHAMPION : RN10PYP4
NGK : PGR5C-11
4.2 (3.5, 4.0)
0.31 (0.26, 0.3)
700 ± 100
BTDC 5° ± 2°2.7L (V6)
6-Cyl., V-type DOHC
3.41 x 2.95 (86.7 x 75.0)
2,656
1 - 2 - 3 - 4 - 5 - 6
CHAMPION : RC10PYPB4
NGK : PFR5N-11
4.4 (3.68, 4.2)
0.31 (0.26, 0.3)
700 ± 100
BTDC 12° ± 5°
SPECIFICATIONS
0.039 - 0.043 in. (1.0 - 1.1 mm)
SH, SG or SG/CD and ABOVE multigrade and fuel-efficient oil