Haynes Hyundai Sonata Automotive Repair Manual 1563927365, 9781563927362

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Includes essential information for today’s more complex vehicles

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

https://archive.org/details/hyundaisonataaut0000imho

Hyundai Sonata Automotive

Repair

Vianual by Tim Imhoff and John H Haynes Member of the Guild of Motoring Writers

Models covered:

Hyundai Sonata - 1999 through 2008 ABCDE FGHIJ KLMNO PQRST

AUTOMOTIVE

proith ae MCESORES MEMBER

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

Acknowledgements Wiring diagrams originated exclusively for Haynes North America, Inc. by Solution Builders.

© Haynes North America, Inc. 2008


ers 2 and 4).

7

12

Oil puddle under engine

1 Oil pan gasket and/or oil pan drain bolt washer leaking (Chapter 2). Nh Oil pressure sending unit leaking (Chapter 2). 3 Valve cover(s) leaking (Chapter 2). 4 — Engine oil seals leaking (Chapter 2). 5 Oil pump housing leaking (Chapter 2).

Engine surges while holding accelerator steady

Intake air leak (Chapter 4). Fuel pump faulty (Chapter 4). Loose fuel injector wire harness connecrs (Chapter 4). AGON= Defective PCM or information sensor (Chapter 6).

0-25

Troubleshooting 13

Engine stalls

1 Fuel filter (orstrainer) clogged and/orwater and impurities in the fuel system (Chapters 1 and 4). 2 Ignition components damp or damaged (Chapter 5). 3 Faulty emissions system components (Chapter 6). 4 Faulty or incorrectly gapped spark plugs

(Chapter 1). 5 Vacuum leak in the fuel injection system, intake manifold or vacuum hoses (Chapters 2 and 4). 6 Valve clearances incorrectly set (Chapter 1).

14

17

Engine runs with oil pressure light on

1 Low oil level (Chapter 1). 2. Short in wiring circuit (Chapter 12). 3 Faulty oil pressure sender (Chapter 2). 4 Worn engine bearings and/or oil pump (Chapter 2).

18

Engine diesels (continues to run) after switching off

1 Excessive engine operating temperature (Chapter 3). 2 Fault in engine management system (Chapter 6).

3 Emissions systems not functioning properly (Chapter 6). 4 Fuel injection system not functioning properly (Chapter 4). es Low tire pressure or incorrect tire size (Chapter 1).

23

Fuel leakage and/or fuel odor

1 Leaking fuel feed or return line (Chapters 1 and 4). 2 Tank overfilled. é 3 Evaporative canister filter clogged (Chapters 1 and 6). 4 Fuel injection system not functioning properly (Chapter 4).

Engine lacks power

Cooling system 1 Fault in engine management system (Chapter 6). 2 Faulty or worn spark plugs (Chapter 1). 3 Fuel injection system malfunction (Chap-

Engine electrical system 24

19

Battery will not hold a charge

t142)r 4) ;

4 Faulty coil(s) (Chapter 5). 5 Brakes dragging (Chapter 9). 6 Automatic transaxle fluid level incorrect (Chapter 1). 7 Fuel filter (or strainer) clogged and/ or impurities in the fuel system (Chapters 1 and 4). 8 Emissions control systems not functioning properly (Chapter 6). 9 Low or uneven cylinder compression pressures (Chapter 2). 10 Obstructed exhaust system (Chapter 4).

1 Alternator drivebelt defective or not adjusted properly (Chapter 1). 2 Battery electrolyte level low (Chapter 1). 3 Battery terminals loose or corroded (Chapter 1). Alternator not charging properly (ChapAS ter 5). 5 Loose, broken or faulty wiring in the charging circuit (Chapter 5). Short in vehicle wiring (Chapter 12). ND Internally defective battery (Chapters 1 and 5).

1 Insufficient coolant in system (Chapter oO 1). 2 Water pump defective (Chapter 3). 3 Radiator core blocked or grille restricted (Chapter 3). 4 Thermostat faulty (Chapter 3). 5 Electric cooling fan blades broken or cracked (Chapter 3). Radiator cap not maintaining proper 6 p ressure (Chapter 3). Fault in engine management system if

(Chapter 6).

25 15

Engine backfires

1 Emission control system not functioning properly (Chapter 6). 2Fault in engine management system (Chapter 6). 3 Faulty spark plug insulator (Chapter 1). 4 Fuel injection system malfunction (Chapter 4). 5 Vacuum leak at fuel injector(s), intake manifold, air control valve or vacuum hoses (Chapters 2 and 4). 6 Valve clearances incorrectly set and/or valves sticking (Chapter 1).

16

Pinging or knocking engine sounds during acceleration or uphill

20

Alternator light fails to go out

Faulty alternator or charging circuit Chapter 5). Alternator drivebelt defective or out of djustment (Chapter 1). Alternator voltage regulator inoperative woOonna —Chapter 5).

21

Alternator light fails to come on when key is turned on

1 Warning light bulb defective (Chapter 12). 2 Fault in the printed circuit, dash wiring or bulb holder (Chapter 12).

Fuel system 1 __ Incorrect grade of fuel. 2 Fault in engine management system (Chapter 6). 3 Fuel injection system faulty (Chapter 4). 4 Improper or damaged spark plug(s) (Chapter 1). § Vacuum leak (Chapters 2 and 4). 6 Defective knock sensor (Chapter 6).

22

Excessive fuel consumption

Dirty or clogged air filter element (Chap—_ ter 1). 2 Fault in engine management system

(Chapter 6).

Overheating

Overcooling

1 Faulty thermostat (Chapter 3). 2 Inaccurate temperature gauge sending unit (Chapter 3)

26

External coolant leakage

1 Deteriorated/damaged hoses; loose clamps (Chapters 1 and 3). 2 Water pump defective (Chapter 3). 3. Leakage from radiator core or coolant reservoir bottle (Chapter 3). 4 Engine drain or water jacket core plugs leaking (Chapter 2).

27

Internal coolant leakage

1 Leaking cylinder head gasket (Chapter 2). 2 Cracked cylinder bore or cylinder head (Chapter 2).

28

Coolant loss

_

Too much coolant in system (Chapter 1).

0-26

Troubleshooting

2 Coolant boiling away because of overheating (Chapter 3). 3 Internal or external leakage (Chapter 3). 4 Faulty radiator cap (Chapter 3).

2 Refer to Chapter 7 for the shift linkage adjustment procedure.

a) The tires are in good condition and prop-

33 29

Transaxle will not downshift with

accelerator pedal pressed to the

Poor coolant circulation

floor 1 2

Inoperative water pump (Chapter 3). Restriction in cooling system (Chapters

1 and 3). 3 Water pump drivebelt defective/out adjustment (Chapter 1).

4

of

Brakes Note: Before assuming that a brake problem exists, make sure that:

These transaxles are electronically controlled. Check for trouble codes stored in the PCM (see Chapter 6).

erly inflated (Chapter 1). b) The front end alignment is correct. c) The vehicle is not loaded with weight in an unequal manner.

39

Vehicle pulls to one side during braking

Thermostat sticking (Chapter 3).

34

Engine will start in gears other than Park or Neutral

Automatic transaxle Note: Due to the complexity of the automatic transaxle, it is difficult for the home mechanic to properly diagnose and service this component. For problems other than the following, the vehicle should be taken to a dealer or transaxle shop.

30

35

Fluid leakage

1 Automatic transaxle fluid is a deep red color. Fluid leaks should not be confused with

engine oil, which can easily be blown onto the transaxle by air flow. 2. Topinpointa leak, first remove all built-up dirt and grime from the transaxle housing with degreasing agents and/or steam cleaning. Then drive the vehicle at low speeds so air flow will not blow the leak far from its source. Raise the vehicle and determine where the leak is coming from. Common areas of leakage are: a) Dipstick tube b) Transaxle oil lines c) Drain plug

31

Transmission

Transaxle fluid brown or has a burned smell

1 Transaxle fluid overheated (Chapter 1). 2 Clutch friction discs and/or bands burned.

Range (TR) sensor mal-

functioning (Chapter 7).

Transaxle slips, shifts roughly, is noisy or has no drive in forward or reverse gears

There are many probable causes for the above problems, but the home mechanic should be concerned with only one possibil-

ity - fluid level. Before taking the vehicle to a repair shop, check the level and condition of the fluid as described in Chapter 1. Correct the fluid level as necessary or change the fluid and filter if needed. If the problem persists, havea professional diagnose the cause.

General shift mechanism problems

1 Chapter 7 deals with checking and adjusting the shift linkage on automatic transaxles. Common problems which may be attributed to poorly adjusted linkage are:

a) Engine starting in gears other than Park or Neutral. b) Indicator on shifter pointing to a gear other than the one actually being used. c) Vehicle moves when in Park.

40

Noise (grinding or high-pitched squeal when the brakes are applied)

1 Front and/or rear disc brake pads worn out. Replace pads with new ones immediately (Chapter 9). 2 Rear drum brake linings worn out. Replace brake shoes with new ones immediately (Chapter 9).

Driveaxles

36

Clicking noise in turns

Worn or damaged (Chapter 8).

37

outboard

41

Shudder or vibration during acceleration

Excessive toe-in (Chapter 10). Worn or damaged inboard or outboard CV joints (Chapter 8). 3. Sticking inboard CV joint assembly (Chapter 8).

38

Vibration at highway speeds

Out-of-balance front wheels and/or tires Chapters 1 and 10). Out-of-round front tires (Chapters 1

nd 10). na Worn CV joint(s) (Chapter 8). woo

Brake roughness or chatter (pedal pulsates)

CV joint

N) —

32

Incorrect tire pressures (Chapter 1). 2 Front end out of alignment (have the front end aligned). 3 Front or rear tires not matched to one another. 4 Restricted brake lines or hoses (Chapter 9). 5 Malfunctioning caliper assembly (Chapter 9). 6 Loose suspension farts (Chapter 10). 7 Loose calipers (Chapter 9). 8 Excessive wear of brake pad material or disc on one side.

Excessive disc lateral runout (Chapter 9). Uneven pad wear (Chapter 9). Defective disc (Chapter 9). WN Out-of-round brake drum (Chapter 9).

42

Excessive brake pedal effort required to stop vehicle

1 Malfunctioning (Chapter 9).

power

brake

booster

2 ‘Partial system failure (Chapter 9). 3 Excessively worn pads or shoes (Chapter 9). 4 Piston in caliper or wheel cylinder stuck or sluggish (Chapter 9). 5 Brake pads or shoes contaminated with oil, grease or brake fluid (Chapter 9).

6 New pads or shoes installed and not yet seated. It will take a while for the new material to seat against the disc or drum.

0-27

Troubleshooting 43 1 2 ters 3

44

Excessive brake pedal travel Partial brake system failure (Chapter 9). Insufficient fluid in master cylinder (Chap1 and 9). Air trapped in system (Chapter 9).

Dragging brakes

a) Tires for wrong pressure

and uneven

wear. b) Steering universal joints from the column to the rack and pinion for loose connectors or wear. c) Front and rear suspension and the steering gear assembly for loose or damaged parts. d) Out-of-round or out-of-balance tires, bent rims and loose and/or rough wheel bear-

ings. 1‘ Incorrect adjustment of brake light switch (Chapter 9). 2 Master cylinder pistons not returning correctly (Chapter 9). 3 Restricted brakes lines or hoses (Chapters 1 and 9). 4 Incorrect parking brake adjustment (Chapter 9). 5 Caliper defective (Chapter 9).

45

Grabbing or uneven braking action

1 Worn pads or shoes (Chapter 9). 2 Contaminated pad or shoe lining material (Chapter 9). 3. Malfunction of proportioning valve (Chapter 9). 4 Binding brake pedal mechanism (Chapter 9).

49

1 Mismatched or uneven tires (Chapter 10). 2 Broken or sagging springs (Chapter 10). 3. Wheel alignment (Chapter 10). 4 Front brake dragging (Chapter 9).

oio

Brake pedal feels spongy when depressed

1 Air in hydraulic lines (Chapter 9). 2 Master cylinder mounting bolts loose (Chapter 9). 3. Master cylinder defective (Chapter 9).

47

Brake pedal travels to the floor with little resistance

1 Little or no fluid in the master cylinder reservoir caused by a leak in the hydraulic system (Chapter 9). 2

Loose, damaged or disconnected brake

lines (Chapter 9). 3 Defective master cylinder (Chapter 9).

48

Parking brake does not hold

Parking brake (Chapters 1 and 9).

improperly

adjusted

Note: Before attempting to diagnose the suspension and steering systems, perform the following preliminary checks:

or excessive tire wear

Wheel makes a thumping noise

1 Blister or bump on tire (Chapter 10). 2. _\Improper shock absorber action (Chapter 10).

52

Shimmy, shake or vibration

1 Tire or wheel out-of-balance or out-ofround (Chapter 10). Loose or worn wheel bearings (ChapNO ters 1, 8 and 10). 3 Worn tie-rod ends (Chapter 10). 4 Worn lower balljoints (Chapters 1 and 10). 5 Excessive wheel runout (Chapter 10). 6 Blister or bump on tire (Chapter 10).

53

Hard steering

1 Worn balljoints, tie-rod ends or steering gear assembly (Chapter 10). 2 Front wheel alignment (Chapter 10). Low tire pressure(s) (Chapters 1 wo and 10).

54

Suspension and steering systems

Abnormal

Wheel alignment (Chapter 10). Sagging or broken springs (Chapter 10). Tire out of balance (Chapter 10). Worn strut damper (Chapter 10). Overloaded vehicle. Tires not rotated regularly. wWhNh Oar =

51 46

Vehicle pulls to one side

Poor returnability of steering to center

1. Worn balljoints or tie-rod ends (Chapter 10).

2 Binding in steering column (Chapter 10). 3 Lack of lubricant in steering gear assembly (Chapter 10). 4 Front wheel alignment (Chapter 10).

55

Abnormal

noise at the front end

1 Worn balljoints or tie-rod ends (Chapter 10). 2 Damaged shock absorber mounting (Chapter 10). 3 Worn control arm bushings or tie-rod ends (Chapter 10). 4 _ Loose stabilizer bar (Chapter 10). 5 Loose wheel nuts (Chapters 1 and 10). 6 Loose suspension bolts (Chapter 10)

56

Wander or poor steering stability

1 Mismatched or uneven tires (Chapter 10). 2 Worn balljoints or tie-rod ends (Chapter 10). 3 Broken or sagging springs (Chapter 10). 4 Wheels out of alignment (Chapter 10).

a7

Erratic steering when braking

Wheel bearings worn (Chapter 10). Broken or sagging springs (Chapter 10). Leaking wheel cylinder or caliper (Chapr 9). Warped brake discs (Chapter 9). ARGON

58

Excessive pitching and/or rolling around corners or during braking

1 Loose stabilizer bar (Chapter 10). 2 Worn strut dampers or mountings (Chapter 10). 3 Broken or sagging springs (Chapter 10). 4 Overloaded vehicle.

59

Suspension bottoms

1 Overloaded vehicle. 2 Worn shock absorbers (Chapter 10). 3 Incorrect, broken or sagging springs (Chapter 10).

60

Cupped tires

1 Front wheel or rear wheel alignment (Chapter 10). 2. Worn shock absorbers (Chapter 10). 3. Wheel bearings worn (Chapter 10). 4 Excessive tire or wheel runout (Chap-

ter 10). 5 Worn balljoints (Chapter 10).

0-28

Troubleshooting

a

61

Excessive tire wear on

outside edge 1

Inflation pressures incorrect (Chapter 1).

2 3.

Excessive speed in turns. Front end alignment incorrect (excessive

toe-in). Have professionally aligned. 4 Suspension arm bent (Chapter 10).

62

3 Loose or damaged steering components (Chapter 10).

63

Tire tread worn in one place

1 2

Tires out of balance. Damaged wheel. Inspect and replace if

necessary. 3 Defective tire (Chapter 1).

Excessive tire wear on

inside edge 1 Inflation pressures incorrect (Chapter 1). 2 Front end alignment incorrect (toe-out). Have professionally aligned.

64

Excessive play or looseness in steering system

1 Wheel bearing(s) worn (Chapter 10). 2 _ Tie-rod end worn (Chapter 10).

en

eee

3 Steering gear loose (Chapter 10). 4 Worn or loose steering intermediate shaft (Chapter 10).

65

Rattling or clicking noise in steering gear

1 2

Steering gear loose (Chapter 10). Steering gear defective.

1-1

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