engine Hyundai Sonata 2006 Workshop Manual

3
WHAT TO DO IN AN EMERGENCY
3
JUMP STARTING!
o If you should accidentally get acid on your
skin or in your eyes, immediately remove
any contaminated clothing and flush the area
with clean 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 solid metal part of the
engine of the vehicle with the discharged
battery away from the battery. Do not con-
nect 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 the engine in the car with the dis-
charged battery 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.
D020A03A-AAT
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.
HNF4001
Booster
batteryDischarged
battery
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34WHAT TO DO IN AN EMERGENCY
IF THE ENGINE OVERHEATS
!!
!
WARNING:
While the engine is running, keep hair,
hands and clothing away from moving parts
such as the fan and drive belts to prevent
injury.
5. If the water pump drive belt is broken or
engine coolant is leaking out, stop the engine
immediately and call the nearest Hyundai
dealer for assistance.
WARNING:
Do not remove the radiator cap when the
engine is hot. This can allow coolant to be
blown out of the opening and cause seri-
ous burns.6. If you cannot find the cause of the overheat-
ing, wait until the engine temperature has
returned to normal. Then, if coolant has been
lost, carefully add coolant to the reservoir
(page 6-9) to bring the fluid level in the
reservoir up to the halfway mark.
7. Proceed with caution, keeping alert for fur-
ther signs of overheating. If overheating
happens again, call a Hyundai dealer for
assistance.
CAUTION:
Serious loss of coolant indicates there is a
leak in the cooling system and this should
be checked as soon as possible by a Hyundai
dealer.
D030A02A-AATIf 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).
nfhma-3.p651/13/2006, 2:41 PM 4

3
WHAT TO DO IN AN EMERGENCY
11
D060J02O-AATAfter Changing Wheels
If you have a tire gauge, remove the
valve cap and check the air pressure. If
the pressure is lower than recom-
mended, drive slowly to the nearest
service station and inflate to the correct
pressure. If it is too high, adjust it until Wheel nut tightening torque:
Steel wheel & aluminium alloy wheel:
65-80 lb.ft (900-1,100 kg.cm)
HNF5016-A
it is correct. Always reinstall the valve
cap after checking or adjusting tire
pressure. If the cap is not replaced, air
may leak from the tire. If you lose a
valve cap, buy another and install it as
soon as possible.
After you have changed wheels, al-
ways secure the flat tire in its place and
return the jack and tools to their proper
storage locations.
IF YOUR VEHICLE MUST BE
TOWEDD080A01O-GATIf your vehicle has to be towed, it should be done
by your Hyundai dealer or a commercial tow
truck service. This will help assure that your
vehicle is not damaged in towing. Also, profes-
sionals are generally aware of local laws gov-
erning towing. In any case, rather than risk
damage to your car, it is suggested that you
show this information to the tow truck operator.
Be sure that a safety chain system is used and
that all local laws are observed.
It is recommended that your vehicle be towed
with a wheel lift and dollies or flatbed equipment
with all the wheels off the ground.
!
CAUTION:
o Your vehicle can be damaged if towed
incorrectly!
o Be sure the transaxle is in neutral.
o When the engine will not start, be sure
the steering is unlocked by placing the
key in the "ACC" position.
nfhma-3.p651/13/2006, 2:41 PM 11

3
WHAT TO DO IN AN EMERGENCY
13
!
D080B02NF
CAUTION:
o Automatic Transaxle:
Be sure to use a towing dolly under the front
wheels.
A vehicle with an automatic transaxle should
never be towed from the rear with the front
wheels on the ground. This can cause se-
rious damage to the transaxle.
3) It is recommended that your vehicle be
towed with all the wheels off the ground.
EMERGENCY TOWINGD080D01NF-AAT
!
D080D02NF-A
For emergency towing when no commercial
tow vehicle is available, attach a tow cable,
chain or strap to the towing hook under the front
of your car. Do not attempt to tow your vehicle
in this manner on any unpaved surface. This
could result in serious damage to your car.
Nor should towing be attempted if the wheels,
drive train, axles, steering or brakes are dam-
aged. Before towing, be sure the transaxle is in
neutral and the key is in "ACC" (with the engine
off) or in the "ON" position (with the engine
running). A driver must be in the towed car to
steer it and operate the brakes.
CAUTION:
If the car is being towed with all four wheels
on the ground, it can be towed only from the
front. Be sure that the transaxle is in neutral.
Do not tow at speeds greater than 30 mph
(50 km/h) and for more than 15 miles (25
km). Be sure the steering is unlocked by
placing the key in the "ACC" position. A
driver must be in the towed vehicle to
operate the steering and brakes.NOTE:Before towing, check the level of the auto-
matic transaxle fluid. If it is below the "HOT"
range on the dipstick, add fluid. If you
cannot add fluid, a towing dolly must be
used.
nfhma-3.p651/13/2006, 2:41 PM 13

5
VEHICLE MAINTENANCE REQUIREMENTS2
F010C01A-AATSpecified Scheduled ProceduresThese 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.
F010A01A-AATService RequirementsTo 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-AATMaintenance RequirementsThe maintenance required for your Hyundai
can be divided into three main areas:
o Specified scheduled procedures
o General checks
o Do-it-yourself maintenance
MAINTENANCE INTERVALS
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5
VEHICLE MAINTENANCE REQUIREMENTS4
SCHEDULED MAINTENANCEF030B03NF-AATR :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.F030A01NF-AATThe 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
VALVE CLEARANCE
SPARK PLUGS (IRIDIUM COATED)
FUEL TANK AIR FILTER
ELECTRONIC THROTTLE CONTROL No.
1
2
3
4
5
6
7
8
9
10MILES X 1000
KILOMETERS X 1000
MONTHS7.5
12
6
R
I
I15
24
12
R
I
I
I
I22.5
36
18
R
I
I30
48
24
R
I
I
I
R
R37.5
60
30
R
R
I
I45
72
36
R
I
I
I
I52.5
84
42
R
I
I
I60
96
48
R
I
I
I
R
I
R67.5
108
54
R
I
I75
120
60
R
R
I
I
I
I82.5
132
66
R
I
I90
144
72
R
I
I
I
R
R97.5
156
78
R
I
I
R105
168
84
R
I
I
I
I
I112.5
180
90
R
R
I
I120
192
96
R
I
I
I
R
I
R127.5
204
102
R
I
I135
216
108
R
I
I
I
I142.5
228
114
R
I
I150
240
120
R
R
I
I
I
R
R
nfhma-5.p654/28/2005, 8:58 AM 4

5
VEHICLE MAINTENANCE REQUIREMENTS6
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
SEVERE DRIVING CONDITIONSA - Repeatedly driving short distance of less than 5miles (8km) in normal
temperature or less than 10miles (16km) in freezing temperature
B - Extensive engine idling or low speed driving for long distances
C - Driving on rough, dusty, muddy, unpaved, graveled or salt- spread roads
D - Driving in areas using salt or other corrosive materials or in very cold weather
E - Driving in sandy areasF040A01NF-AATThe 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 - Driving in heavy traffic area over 90°F (32°C)
G - Driving on uphill, downhill, or mountain road
H - Towing a Trailer, or using a camper, or roof rack
I - Driving as a patrol car, taxi, other commercial use or vehicle towing
J - Driving over 100 MPH (170 Km/h)
K - Frequently driving in stop-and-go conditionsENGINE 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
DRIVE SHAFTS AND BOOTS
MANUAL TRANSAXLE OIL
AIR CONDITIONER FILTER (FOR EVAPORATOR AND BLOWER UNIT)
AUTOMATIC TRANSAXLE FLUID
MAINTENANCE ITEM
R
I
R
I
I
I
I
R
R
R
EVERY 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)
MORE FREQUENTLY
EVERY 30,000 MILES (48,000 KM)
DRIVING
CONDITION MAINTENANCE
INTERVALS MAINTENANCE
OPERATION
A, B, C, D, E, F, G, H, I, K
C, E
B, H
C, D, G, H
C, D, G, H
C, D, E, F, G, H, I
C, D, E, F
A, C, D, E, F, G, H, I, J
C, E
A, C, E, F, G, H, I
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5
VEHICLE MAINTENANCE REQUIREMENTS
7
F060D01A-AATo Fuel Lines, Fuel Hoses and Connec-
tionsCheck the fuel lines, fuel hoses and connec-
tions for leakage and damage. Have a trained
technician replace any damaged or leaking
parts immediately.F060B01NF-GATo Drive BeltsInspect 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.
F060M01A-AATo Engine Oil and FilterThe 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 FilterA 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
HosesInspect 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.
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS
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5
VEHICLE MAINTENANCE REQUIREMENTS8
F070G02A-AATo Brake FluidCheck 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.F070F01A-AATo Brake Hoses and LinesVisually check for proper installation, chafing,
cracks, deterioration and any leakage. Replace
any deteriorated or damaged parts immedi-
ately.
F070E06A-AATo Automatic Transaxle FluidThe 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 HYUNDAI
GENUINE ATF SP III, DIAMOND ATF SP III, SK
ATF SP III or other brands meeting the SP III
specification approved by Hyundai Motor Co.
when adding or changing fluid. Using the wrong
ATF may result in damage to the ATM.
F070H01A-AATo Rear Brake Drums and Linings/
Parking BrakeCheck 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.
F070C01A-AATo CoolantThe coolant should be changed at the intervals
specified in the maintenance schedule.
F060J01A-AATo Spark PlugsMake sure to install new spark plugs of the
correct heat range.F060H01A-AATo Air Cleaner FilterA Genuine Hyundai air cleaner filter is recom-
mended when the filter is replaced.F060G01A-AATo Vapor Hose and Fuel Filler CapThe 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.
F070D01A-AATo Manual Transaxle OilInspect 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.
F060N02E-AATo Valve ClearanceInspect excessive valve noise and/or engine
vibration and adjust if necessary. A qualified
technician should perform the operation.
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5
VEHICLE MAINTENANCE REQUIREMENTS
9
F070L01A-AATo Suspension Mounting BoltsCheck the suspension connections for loose-
ness or damage. Retighten to the specified
torque.F070K01A-AATo Exhaust Pipe and MufflerVisually 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.F070J01A-AATo Brake Pads, Calipers and RotorsCheck the pads for excessive wear, discs for
run out and wear, and calipers for fluid leakage.
F070Q01A-AATo Air Conditioning RefrigerantCheck the air conditioning lines and connec-
tions for leakage and damage. Check air con-
ditioning performance according to the relevant
shop manual if necessary.
F070P01A-AATo Drive Shafts and BootsCheck the drive shafts, boots and clamps for
cracks, deterioration, or damage. Replace any
damaged parts and, if necessary, repack the
grease.F070N01A-AATo Power Steering Pump, Belt and HosesCheck 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.F070M01Y-AATo Steering Gear Box, Linkage & Boots/
Lower Arm Ball Joint, Upper Arm Ball
JointWith 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.
nfhma-5.p654/28/2005, 8:59 AM 9