spark Hyundai Sonata 2004 Owner's Manual

1- 58 FEATURES OF YOUR HYUNDAI
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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

2- 14 DRIVING YOUR HYUNDAI
C160G01A-AATTo Keep Locks from Freezing
To keep the locks from freezing, squirt an
approved de-icer fluid or glycerine into the key
opening. If a lock is covered with ice, squirt it with
an approved de-icing fluid to remove the ice. If
the lock is frozen internally, you may be able to
thaw it out by using a heated key. Handle the
heated key with care to avoid burning the
fingers.
C160D01A-AAT
Check Battery and Cables
Winter puts additional burdens on the battery
system. Visually inspect the battery and cables
as described in Section 6. The level of charge
in your battery can be checked by your Hyundai
dealer or a service station.
C160F01A-AATCheck Spark Plugs and Ignition
System
Inspect your spark plugs as described in Sec-
tion 6 and replace them if necessary. Also
check all ignition wiring and components to be
sure they are not cracked, worn or damaged in
any way.
C160E01A-AATChange to "Winter Weight" Oil if
Necessary
In some climates it is recommended that a lower
viscosity "winter weight" oil be used during cold
weather. See Section 9 for recommendations.
If you aren't sure what weight oil you should use,
consult your Hyundai dealer.
C160C01A-AATUse High Quality Ethylene Glycol
Coolant
Your Hyundai is delivered with high quality
ethylene glycol coolant in the cooling system. It
is the only type of coolant that should be used
because it helps prevent corrosion in the cool-
ing system, lubricates the water pump and
prevents freezing. Be sure to replace or replen-
ish your coolant in accordance with the main-
tenance schedule in Section 5. Before winter,
have your coolant tested to assure that its
freezing point is sufficient for the temperatures
anticipated during the winter.
C160B01A-AATSnowy or Icy Conditions
To drive your vehicle in deep snow, it may be
necessary to use snow tires or to install tire
chains on your tires. If snow tires are needed,
it is necessary to select tires equivalent in size
and type of the original equipment tires. Failure
to do so may adversely affect the safety and
handling of your car. Furthermore, speeding,
rapid acceleration, sudden brake applications,
and sharp turns are potentially very hazardous
practices.
During deceleration, use engine braking to the
fullest extent. Sudden brake applications on
snowy or icy roads may cause skids to occur.
You need to keep sufficient distance between
the vehicle in operation in front and your vehicle.
Also, apply the brake gently. It should be noted
that installing tire chains on the tire will provide
a greater driving force, but will not prevent side
skids.
NOTE:Tire chains are not legal in all states. Check
state laws before fitting tire chains.

3- 2 WHAT TO DO IN AN EMERGENCY
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D010A01A-AATIF THE ENGINE WILL NOT START
D010B01A-AATIf Engine Doesn't Turn Over or Turns
Over Slowly
D010C01Y-AATIf Engine Turns Over Normally but Does
Not Start
1. Check fuel level.
2. Check all connectors at ignition, coil and
spark plugs. Re-connect any that may be
disconnected or loose.
3. Check the fuel line in the engine room.
4. If engine still refuses to start, call a Hyundai
dealer or seek other qualified assistance.
D010D01A-AATIf Engine Stalls While Driving
1. Reduce your speed gradually, keeping a
straight line. Move cautiously off the road to
a safe place.
2. Turn on your emergency flashers.
3. Try to start the engine again. If your vehicle
will not start, contact a Hyundai dealer or
seek other qualified assistance.
WARNING:If the engine will not start, do not push or
pull the car to start it. This could result in a
collision or cause other damage. In addi-
tion, push or pull starting may cause the
catalytic converter to be overloaded and
create a fire hazard.
1. If your car has an automatic transaxle, be
sure the gear selector lever is in "N" or "P"
and the emergency brake is set.2. Check the battery connections to be sure
they are clean and tight.
3. Turn on the interior light. If the light dims or
goes out when you operate the starter, the
battery is discharged.
4. Check the starter connections to be sure
they are securely tightened.
5. Do not push or pull the vehicle to start it. See
instructions for "Jump Starting" on the fol-
lowing pages.
D020A02A-AATJUMP STARTING
WARNING:
The gas produced by the battery during the
jump-start operation is highly explosive. If
these instructions are not followed exactly,
serious personal injury and damage to the
vehicle may occur! If you are not sure how
to follow this procedure, seek qualified
assistance. Automobile batteries contain
sulfuric acid. This is poisonous and highly
corrosive. When jump starting, wear pro-
tective glasses and be careful not to get
acid on yourself, your clothing or on the car.
D010B02YHEF194
Battery

WHAT TO DO IN AN EMERGENCY 3- 3
o If you should accidentally get acid on your
skin or in your eyes, immediately remove
any contaminated clothing and flush the area
with clear water for at least 15 minutes. Then
promptly obtain medical attention. If you
must be transported to an emergency facil-
ity, continue to apply water to the affected
area with a sponge or cloth.
o The gas produced by the battery during the
jump-start operation is highly explosive. Do
not smoke or allow a spark or an open flame
in the vicinity.
o The battery being used to provide the jump
start must be 12-volt. If you cannot deter-
mine that it is a 12-volt battery, do not attempt
to use it for the jump start.
o To jump start a car with a discharged battery,
follow this procedure exactly:
1. If the booster battery is installed in another
vehicle, be sure the two vehicles are not
touching.
2. Turn off all unnecessary lights and acces-
sories in both vehicles.
3. Attach the clamps of the jumper cable in the
exact location shown on the illustration. First,
attach one clamp of the jumper cable to the
positive (+) post or cable of the discharged
battery. Then attach the other end of the
same cable to the positive (+) post or cable
of the booster battery. Next, using the other
cable, attach one clamp to the negative (-)
post or cable of the booster battery. Then
attach the other end of that cable to a solidmetal part of the engine away from the
battery. Do not connect the cable to any
moving part.
4. Start the engine in the car with the booster
battery and let it run for a few minutes. This
will help to assure that the booster battery is
fully charged. During the jumping operation,
run the engine in this vehicle at about 2,000
rpm.
5. Start your engine using the normal starting
procedure. After the engine starts, leave the
jumper cables connected and let the engine
run at fast idle or about 2,000 rpm for several
minutes.
6. Carefully remove the jumper cables in the
reverse order of attachment.
If you do not know why your battery became
discharged (because the lights were left on,
etc.), have the charging system checked by
your Hyundai dealer.D030A01A-AATIF THE ENGINE OVERHEATS
If your temperature gauge indicates overheat-
ing, you experience a loss of power, or hear loud
pinging or knocking, the engine is probably too
hot. If this happens, you should:
1. Pull off the road and stop as soon as it is safe
to do so.
2. Place the gear selector lever in "P" (auto-
matic), or neutral (manual transaxle) and set
the parking brake. If the air conditioning is on,
turn it off.
3. If engine coolant is running out under the car
or steam is coming out from the hood, stop
the engine. Do not open the hood until the
coolant has stopped running or the steaming
has stopped. If there is no visible loss of
engine coolant and no steam, leave the
engine running and check to be sure the
engine cooling fan is operating. If the fan is
not running, turn the engine off.
4. Check to see if the water pump drive belt is
missing. If it is not missing, check to see that
it is tight. If the drive belt seems to be
satisfactory, check for coolant leaking from
the radiator, hoses or under the car. (If the
air conditioning had been in use, it is normal
for cold water to be draining from it when you
stop).

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.

5- 6 VEHICLE MAINTENANCE REQUIREMENTS
SEVERE DRIVING CONDITIONSA - 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
F040A04Y-AATMAINTENANCE 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
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
I - Driving for patrol car, taxi or commercial car and vehicle towing
J - Driving over 100 mph 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)
MAINTENANCE ITEM
R
R
R
I
I
I
I
R
R
REVERY 3,000 MILES (4,800 KM) OR 3 MONTHS
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
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
DRIVING
CONDITION MAINTENANCE
INTERVALS MAINTENANCE
OPERATION
A, B, C, F, H
C, E
B, H
C, D, G, H
C, D, G, H
C, D, E, F, G
C, E, F
A, C, D, E, F, G, H, I, J
A, C, E, F, G, H, I
C, E

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.

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

DO-IT-YOURSELF MAINTENANCE 6- 9
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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

6- 10 DO-IT-YOURSELF MAINTENANCE
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G060C04Y-AATChanging 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 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.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.
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.6. To install the new spark plug, guide the
socket down over the spark plug, being
careful not to damage the ceramic insulator.
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.
G060C01O
G060C02OG060C03O