check engine Hyundai Sonata Hybrid 2015 Workshop Manual

721
Maintenance
Parking brake
Inspect the parking brake system includ-
ing the parking brake pedal and cables.
Brake discs, pads, calipers and
rotors
Check the pads for excessive wear, discs
for run out and wear, and calipers for fluid
leakage.
Exhaust pipe and muffler
Visually inspect the exhaust pipes, muf-
fler 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.
Suspension mounting bolts
Check the suspension connections for
looseness or damage. Retighten to the
specified torque.
Steering gear box, linkage &
boots/lower arm ball joint
With the vehicle stopped and engine off,
check for excessive free-play in the
steering wheel.
Check the linkage for bends or damage.
Check the dust boots and ball joints for
deterioration, cracks, or damage.
Replace any damaged parts.
Drive shafts and boots
Check the drive shafts, boots and clamps
for cracks, deterioration, or damage.
Replace any damaged parts and, if nec-
essary, repack the grease.
Air conditioning refrigerant
Check the air conditioning lines and con-
nections for leakage and damage.

Maintenance
22
7
ENGINE OIL
WARNING - Radiator hose
Be very careful not to touch the
radiator hose when checking or
adding the engine oil as it may be
hot enough to burn you.
CAUTION
Do not overfill with engine oil.
Engine damage may result.
Checking the engine oil level
1. Be sure the vehicle is on level ground.
2. Start the engine and allow it to reach normal operating temperature.
3. Turn the engine off and wait for a few minutes (about 5 minutes) for the oil to
return to the oil pan.
4. Pull the dipstick out, wipe it clean, and re-insert it fully. 5. Pull the dipstick out again and check
the level. The level should be between
F and L.
If it is near or at L, add enough oil to bring
the level to F.Do not overfill.
Use a funnel to help prevent oil from
being spilled on engine components.
Use only the specified engine oil. (Refer to “Recommended lubricants and capaci- ties” in section 8.)
OYFH071003NOYFH071004N
CAUTION
Do not spill engine oil, when addingor changing engine oil. If you spillengine oil on the engine room, wipeit off immediately.

Maintenance
24
7
COOLANT
Inverter coolant
The high-pressure cooling system has a
reservoir filled with year-round antifreeze
coolant. The reservoir is filled at the fac-
tory.
Check the antifreeze protection and
coolant level. If it is near or at MIN, add enough coolant
between MIN and MAX and check the
cooling system for air bleed at an author-
ized HYUNDAI dealer.
Engine coolant
The high-pressure cooling system has a
reservoir filled with year-round antifreeze
coolant. The reservoir is filled at the factory.
Check the antifreeze protection and
coolant level per every day, at the begin-
ning of the winter season, and before
traveling to a colder climate.
Checking the coolant level
CAUTION
Do not mix-up the caps of engine
coolant and inverter coolant.
If mixed-up it could create a coolantcirculation problem for the engineor Hybrid system.
CAUTION
When adding coolant, be carefulnot to overfill.
WARNING
Removing radiator
and inverter coolant
cap
Never attempt to remove the radi- ator and/or inverter coolant cap
while the engine is operating or
hot. Doing so might lead to cool-
ing system and engine damage
and could result in serious per-
sonal injury from escaping hot
coolant or steam.
(Continued)
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725
Maintenance
Check the condition and connections of
all cooling system hoses and heater
hoses. Replace any swollen or deterio-
rated hoses.
The coolant level should be filled
between F and L marks on the side of the
coolant reservoir when the engine is cool.
If the coolant level is low, add enough
distilled (deionized) water to provide pro-
tection against freezing and corrosion.
Bring the level to F, but do not overfill. If
frequent additions are required, see an
authorized HYUNDAI dealer for a cooling
system inspection.
OYFH071005N
(Continued)
The engine coolant and/or invertercoolant level is influenced by
hybrid system temperature. Before
filling the engine coolant and/or
inverter coolant, turn the hybrid
vehicle off, fill the engine coolant
and/or inverter coolant carefully.
Turn the engine off and wait until it cools down. Use extreme care
when removing the radiator and/or
inverter coolant cap. Wrap a thick
towel around it, and turn it coun-
terclockwise slowly to the first
stop. Step back while the pressure
is released from the cooling sys-
tem. When you are sure all the
pressure has been released, press
down on the cap, using a thick
towel, and continue turning coun-
terclockwise to remove it.
Even if the engine is not operat- ing, do not remove the radiator
and/or inverter coolant cap or the
drain plug while the engine and
radiator are hot. Hot coolant and
steam may still blow out under
pressure, causing serious injury.WARNING
The electric motor
(cooling fan) is con-
trolled by engine
coolant temperature,
refrigerant pressure
and vehicle speed. It may some-
times operate even when the
engine is not running. Use extreme
caution when working near the
blades of the cooling fan so that
you are not injured by the rotating
fan blades. As the engine coolant
temperature decreases, the electric
motor will automatically shut off.
This is a normal condition.

727
Maintenance
BRAKE FLUID
Checking the brake fluid level
Check the fluid level in the reservoir peri-
odically. The fluid level should be
between MAX and MIN marks on the
side of the reservoir. To check the brake
fluid exactly, after stopping the vehicle,
apply the brake pedal a few times and
then check the fluid level.
Before removing the reservoir cap and
adding brake fluid, clean the area around
the reservoir cap thoroughly to prevent
brake fluid contamination.
If the level is low, add fluid to the MAX
level. The level will fall with accumulated
mileage. This is a normal condition asso-
ciated with the wear of the brake linings.
If the fluid level is excessively low, have
the brake system checked by an author-
ized HYUNDAI dealer.
Use only the specified brake fluid. (Referto “Recommended lubricants or capaci-ties” in section 8.)
Never mix different types of fluid.
WARNING - Brake fluid
When changing and adding brake
fluid, handle it carefully. Do not let it
come in contact with your eyes. If
brake fluid should come in contact
with your eyes, immediately flush
them with a large quantity of fresh
tap water. Have your eyes examined
by a doctor as soon as possible.
WARNING - Loss of brake
fluid
In the event the brake system
requires frequent additions of fluid,
the vehicle should be inspected by
an authorized HYUNDAI dealer.CAUTION
Do not allow brake fluid to contactthe vehicle's body paint, as paintdamage will result. Brake fluid,which has been exposed to open air for an extended time should neverbe used as its quality cannot be guaranteed. It should be disposedof properly. Don't put in the wrongkind of fluid. A few drops of miner- al-based oil, such as engine oil, inyour brake system can damage brake system parts.
CAUTION
Do not overfill the brake fluid. Brakesystem damage may occur if thebrake fluid level exceeds the Max fill level.
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Maintenance
36
7
Reset items
Items should be reset after the 12V bat-
tery has been discharged or the 12V bat-
tery has been disconnected.
Auto up/down window (See section 4)
Sunroof (See section 4)
Trip computer (See section 4)
Climate control system
(See section 4)
Clock (See section 4)
Audio (See section 4)WARNING
Before performing maintenance or recharging the 12V battery,
turn off all accessories and stop
the engine.
The negative battery cable must be removed first and installed
last when the 12V battery is dis-
connected.
Operation related to the 12V bat- tery should be done in an author-
ized HYUNDAI dealer.
WARNING- Recharging12V battery
When recharging the battery,
observe the following precautions:
The battery must be removed
from the vehicle and placed in an
area with good ventilation.
Do not allow cigarettes, sparks, or flame near the battery.
Watch the battery during charg- ing, and stop or reduce the charg-
ing rate if the battery cells begin
gassing (boiling) violently or if
the temperature of the electrolyte
of any cell exceeds 120°F (49°C).
Wear eye protection when check- ing the battery during charging.
Disconnect the battery charger in the following order.
1. Turn off the battery charger main switch.
2. Unhook the negative clamp from the negative battery terminal.
3. Unhook the positive clamp from the positive battery terminal.

751
Maintenance
FUSES
A vehicle’s electrical system is protected
from electrical overload damage by fuses.
This vehicle has 2 fuse panels, one locat-
ed in the driver’s side panel bolster, the
other in the engine compartment.
If any of your vehicle’s lights, accessories,
or controls do not work, check the appro-
priate circuit fuse. If a fuse has blown, the
element inside the fuse will be melted.
If the electrical system does not work,
first check the driver’s side fuse panel.Always replace a blown fuse with one of
the same rating.
If the replacement fuse blows, this indi-
cates an electrical problem. Avoid using
the system involved and immediately
consult an authorized HYUNDAI dealer.
Three kinds of fuses are used: blade type
for lower amperage rating, cartridge type,and multi fuse for higher amperage ratings.
✽ ✽ NOTICE
The actual fuse/relay panel label may
differ from equipped items.
WARNING - Fuse
replacement
Never replace a fuse with anything
but another fuse of the same rat-
ing.
A higher capacity fuse could cause damage and possibly a fire.
Never install a wire or aluminum foil instead of the proper fuse -
even as a temporary repair. It may
cause extensive wiring damage
and a possible fire.
CAUTION
Do not use a screwdriver or anyother metal object to remove fusesbecause it may cause a short circuit and damage the system.
CAUTION
When replacing a blown fuse or relay with a new one, make surethe new fuse or relay fits tightly into the clips. The incomplete fas-tening fuse or relay may cause the vehicle wiring and electric sys-tems damage and a possible fire.
Do not remove fuses, relays and terminals fastened with bolts ornuts. The fuses, relays and termi-nals may be fastened incomplete- ly, and it may cause a possiblefire. If fuses, relays and terminals fastened with bolts or nuts areblown, consult with an authorized HYUNDAI dealer.
Do not input any other objects except fuses or relays intofuse/relay terminals such as a driv-er or wiring. It may cause contact failure and system malfunction.
OBK079042
Normal
Normal
Blade type
Cartridge type
Multi fuse Blown
Blown
Normal Blown

Maintenance
52
7
Instrument panel fuse replace-
ment
1. Turn the engine start/stop button and
all other switches off.
2. Open the fuse panel cover. 3. Pull the suspected fuse straight out.
Use the removal tool provided in the
engine compartment fuse panel.
4. Check the removed fuse; replace it if it is blown.
5. Push in a new fuse of the same rating, and make sure it fits tightly in the clips.
If it fits loosely, consult an authorized
HYUNDAI dealer.
If you do not have a spare, use a fuse of the same rating from a circuit you maynot need for operating the vehicle, suchas the cigarette lighter fuse.
If the headlights or other electrical com-
ponents do not work and the fuses are
OK, check the fuse panel in the engine
compartment. If a fuse is blown, it must
be replaced.
Memory fuse
Your vehicle is equipped with a memory
fuse to prevent 12V battery discharge if
your vehicle is parked without being
operated for prolonged periods. Use the
following procedures before parking the
vehicle for prolonged periods.
1. Turn off the engine.
2. Turn off the headlights and tail lights.
3. Open the driver’s side panel cover and pull up the memory fuse.
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753
Maintenance
✽
✽NOTICE
• If the memory fuse is pulled up from
the fuse panel, the warning chime,
audio, clock and interior lamps, etc.,
will not operate. Some items must be
reset after replacement. Refer to
“Battery” in this section.
• Even though the memory fuse is pulled up, the battery can still be dis-
charged by operation of the head-
lights or other electrical devices.
Engine compartment fuse
replacement
1. Turn the engine start/stop button and
all other switches off.
2. Remove the fuse panel cover by pressing the tab and pulling up. 3. Check the removed fuse; replace it if it
is blown. To remove or insert the fuse,
use the fuse puller in the engine com-
partment fuse panel.
4. Push in a new fuse of the same rating, and make sure it fits tightly in the clips.
If it fits loosely, consult an authorized
HYUNDAI dealer.
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CAUTION
After checking the fuse panel in theengine compartment, securelyinstall the fuse panel cover. If not, electrical failures may occur fromwater contact.

759
Maintenance
Description Fuse ratingProtected component
FUSE1 ESC 40A EBS Control Module2 ESC 30A EBS Control Module2 AHB 30A AHB Control Module4 ECU 10A PCM2 TCU 15A Transaxle Range Switch3ESC 10A Stop Lamp Switch, Multipurpose Check Connector, EBS Control Module2 OIL PUMP 10A Hybrid Fuse & Relay Box (OPCU Relay), Electric Oil Pump Unit
B/UP LAMP 10A A/V & Navigation Head Unit, Rear Combination Lamp (IN) LH/RH, BCM, Electro Chr\
omic Mirror
1 ECU 30A Engine Control Relay
IGN COIL 20A Ignition coil #1/#2/#3/#4, Condenser
1 SENSOR 15A Oxygen Sensor (Up/Down), Oil control Valve (1/2), Purge Control Solenoid Valve, Crankshaft
Position Sensor, CCV
2 SENSOR 15A Camshaft Position Sensor (1/2)
INJECTOR 15A Injector #1/#2/#3/#4, F/PUMP Relay F/PUMP 20A F/PUMP Relay EWP 10A EWP Relay
HORN 15A Burglar Alarm Horn Relay, Horn Relay
SPARE 25A -
SPARE 20A -
SPARE 15A -
SPARE 10A -