2003 Hyundai Sonata light

6- 4 DO-IT-YOURSELF MAINTENANCE
G020C01A-AATVehicle Interior
The following should be checked each time
when the vehicle is driven:
o Lights operation
o Windshield wiper operation
o Horn operation
o Defroster, heating system operation (and air
conditioning, if installed)
o Steering operation and condition
o Mirror condition and operation
o Turn signal operation
o Accelerator pedal operation
o Brake operation, including parking brake
o Manual transaxle operation, including clutch
operation
o Automatic transaxle operation, including
"Park" mechanism operation
o Seat control condition and operation
o Seat belt condition and operation
o Sunvisor operation
If you notice anything that does not operate
correctly or appears to be functioning incor-
rectly, inspect it carefully and seek assistance
from your Hyundai dealer if service is needed.
G020B01A-AATVehicle Exterior
The following should be checked monthly:
o Overall appearance and condition
o Air filter condition
o Wheel condition and wheel nut torque
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and body corrosion
o Fluid leaks
o Door and hood lock condition
o Tire pressure and condition (including spare
tire)
G020A01A-AATGENERAL CHECKS
Engine Compartment
The following should be checked regularly:
o Engine oil level and condition
o Transaxle fluid level and condition
o Brake fluid level
o Clutch fluid level
o Engine coolant level
o Windshield washer fluid level
o Accessory drive belt condition
o Engine Coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level
o Battery condition

6- 16 DO-IT-YOURSELF MAINTENANCE
G150A01A-AATCHECKING STEERING WHEEL
FREE-PLAYG140D01A-AATChecking the Compressor Drive Belt
G140C01A-AATLubrication
To lubricate the compressor and the seals in the
system, the air conditioning should be run for at
least 10 minutes each week. This is particularly
important during cool weather when the air
conditioning system is not otherwise in use.
G140B01A-AATChecking the Air Conditioning Opera-
tion
1. Start the engine and let it run at a fast idle for
several minutes with the air conditioning set
at the maximum cold setting.
2. If the air coming out of the in-dash vents is
not cold, have the air conditioning system
inspected by your Hyundai dealer.
CAUTION:Running the air conditioning system for
extended periods of time with a low refrig-
erant level may damage the compressor.
!
When the air conditioning is being used regu-
larly, the compressor drive belt tension should
be checked at least once a month with the
engine turned off.
To check the drive belt tension, press down on
the belt halfway between the engine crankshaft
and compressor pulleys. Pressing with your
finger, you should not be able to deflect this belt
anymore than 1/3 of an inch. If you have the
instruments to check it, with a force of 22 lb.
(98N), the deflection should be 0.315 inches
(approx 8.0 mm). If the belt is too loose, have it
adjusted by your Hyundai dealer.To check the steering wheel free-play, stop the
car with the wheels pointed straight ahead and
gently move the steering wheel back and forth.
Use very light finger pressure and be sensitive
to changes in resistance that mark the limits of
the free-play. If the free-play is greater than
specified, have it inspected by your Hyundai
dealer and adjusted or repaired if necessary.
HSM396
G150A01Y
Maximum
1.18 in.
(30 mm)
DOHC V6
Eng.pulleyCOMP
Eng.pulleyCOMP 0.315 in.
Auto tensioner

DO-IT-YOURSELF MAINTENANCE 6- 17
G160A01A-AATCHECKING CLUTCH PEDAL
FREE-PLAY
With the engine off, press lightly on the clutch
pedal until you feel a change in resistance. This
is the clutch pedal free-play. The free-play
should be within the limits specified in the illus-
tration. If it is not, have it inspected by your
Hyundai dealer and adjusted or repaired if
necessary.
G170A02A-AATCHECKING BRAKE PEDAL
FREE-PLAY
With the engine off, press down on the brake
pedal several times to reduce the vacuum in the
brake booster.
Then, using your hand, press down slowly on
the brake pedal until you feel a change in
resistance. This is the brake pedal free-play.
The free-play should be within the limits speci-
fied in the illustration above. If it is not, have it
inspected by your Hyundai dealer and adjusted
or repaired if necessary.
G160A01EHXGS508
0.24~0.51 in.
(6~13 mm)0.12~0.31 in.
(3~8 mm)
G180A01A-AATCHECKING BRAKE PEDAL
CLEARANCE
You need a helper to check the brake pedal
clearance. With the engine running, have your
helper press down on the brake pedal several
times and then hold it down with a force of about
110 lbs (50 kg, 490 N). The brake pedal clear-
ance is the distance from the top surface of the
brake pedal to the asphalt sheeting under the
floor mat.
If the brake pedal clearance is not within the
limits specified in the illustration, have it in-
spected by your Hyundai dealer and adjusted
or repaired if necessary.
G180A01L
2.95 in. (75 mm)

6- 18 DO-IT-YOURSELF MAINTENANCE
G200A01Y-GATCHECKING AND REPLACING
FUSES
Replacing a Fusible Link
G200B01Y-GAT
Replacing Accessory Fuse
G190A01A-AATCHECKING DRIVE BELTS
Drive belts should be checked periodically for
proper tension and adjusted if necessary. At the
same time, belts should be examined for cracks,
wear, fraying or other evidence of deterioration
and replaced if necessary.
Belt routing should also be checked to be sure
there is no interference between the belts and
other parts of the engine. After a belt is replaced,
the new belt should be adjusted again after two
or three weeks to eliminate slack resulting from
initial stretching after use.A fusible link will melt if the electrical circuits from
the battery are ever overloaded, thus prevent-
ing damage to the entire wiring harness. (This
could be caused by a short in the system
drawing too much current.) If this ever happens,
have a Hyundai dealer determine the cause,
repair the system and replace the fusible link.
The fusible links are located in a under hood
junction box for easy inspection.
!
The instrument panel junction box for the lights
and other electrical accessories will be found
low on the dashboard on the driver’s side. Inside
the box you will find a list showing the circuits
protected by each fuse.
CAUTION:When replacing a fusible link, never use
anything but a new fusible link with the
same or lower amperage rating. Never use
a piece of wire or a higher-rated fusible link.
This could result in serious damage and
create a fire hazard.
HSM396
G200A01L
G200B01Y
Bad
Good
V6
Power
steeringPower
steering Auto
tensioner
Generator
Generator
Eng.pulley Eng.pulleyCOMP COMPEng.coolant
0.30~0.48in.
0.24~0.35in.
DOHC

DO-IT-YOURSELF MAINTENANCE 6- 19
!
If any of your car’s lights or other electrical
accessories stop working, a blown fuse could
be the reason. If the fuse has burned out, you
will see that the metal strip inside the fuse has
burned through. If you suspect a blown fuse,
follow this procedure:
1. Turn off the ignition and all other switches.
2. Open the instrument panel junction box and
examine each fuse. Remove each fuse by
pulling it toward you (a small "fuse puller" tool
is contained in the fuse box to simplify this
operation).
3. Be sure to check all other fuses even if you
find one that appears to have burned out.
4. Replace the blown fuse by pressing a new
fuse of the same rating into place. The fuse
should be a snug fit. If it is not, have the fuse
clip repaired or replaced by a Hyundai dealer.
HXGS416Fuse Puller
G210A01A-AATCHECKING THE BATTERY
WARNING:
Batteries can be dangerous! When working
with batteries, carefully observe the follow-
ing precautions to avoid serious injuries.
The fluid in the battery contains a strong solution
of sulfuric acid, which is poisonous and highly
corrosive. Be careful not to spill it on yourself or
the car. If you do spill battery fluid on yourself,
immediately do the following:
o If battery fluid is on your skin, flush the
affected areas with water for at least 15
minutes and then seek medical assistance.
o If battery fluid is in your eyes, rinse out your
eyes with water and get medical assistance
as soon as possible. While you are being
driven to get medical assistance, continue to
rinse your eyes by using a sponge or soft
cloth saturated with water.
o If you swallow battery fluid, drink a large
quantity of water or milk followed by milk of
magnesia, eat a raw egg or drink vegetable
oil. Get medical assistance as soon as
possible. If you do not have a spare fuse, you may be
able to borrow a fuse of the same or lower
rating from an accessory you can tempo-
rarily get along without (the radio or cigarette
lighter, for example). Always remember to
replace the borrowed fuse.
CAUTION:A burned-out fuse indicates that there is a
problem in the electrical circuit. If you re-
place a fuse and it blows as soon as the
accessory is turned on, the problem is
serious and should be referred to a Hyundai
dealer for diagnosis and repair. Never re-
place a fuse with anything except a fuse
with the same or a lower amperage rating.
A higher capacity fuse could cause damage
and create a fire hazard.
NOTE:See page 6-29 for the junction box descrip-
tions.
!
G200B03Y
GoodBurned out

6- 20 DO-IT-YOURSELF MAINTENANCE
!
!
G230A03A-AATPOWER STEERING FLUID LEVEL
G220B01A-AATChecking Engine Cooling Fan
The engine cooling fan should come on auto-
matically if the engine coolant temperature is
high.
G220A01A-AATCHECKING ELECTRIC COOLING
FANS
G220C01A-AATChecking Condenser Cooling Fan
The condenser coolant fan should come on
automatically whenever the air conditioning is in
operation.
G210B02A-AATChecking the Battery
Keep the battery clean. Any evidence of corro-
sion around the battery posts or terminals
should be removed using a solution of house-
hold baking soda and warm water. After the
battery terminals are dry, cover them with a light
coating of grease. While batteries are being charged (either by a
battery charger or by the vehicle's generator),
they produce explosive gases. Always ob-
serve these warnings to prevent injuries from
occurring:
o Charge batteries only in a well ventilated
area.
o Do not permit flames, sparks or smoking in
the area.
o Keep children away from the area.
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.
The power steering fluid level should be checked
regularly. To check the power steering fluid
level, be sure the engine is "OFF", then check
to make certain that the power steering fluid
level is between the "MAX" and "MIN" level
markings on the fluid reservoir.
NOTE:Grinding noise from the power steering
pump may be heard immediately after the
engine is started in extremely cold condi-
tions (below - 4°F). If the noise stops during
warm up, there is no abnormal function in
the system. It is due to a power steering
fluid characteristic in extremely cold condi-
tions.
G230A03Y
PROPOSITION 65 WARNING:Battery posts, terminals, and related acces-
sories contain lead and lead compounds,
chemicals known to the state of California
to cause cancer and reproductive harm.
Wash hands after handling.
!

DO-IT-YOURSELF MAINTENANCE 6- 21
G250A01A-AATFOR MORE INFORMATION ABOUT
YOUR HYUNDAI
If you desire additional information about main-
taining and servicing your Hyundai, you may
purchase a factory Shop Manual at your Hyundai
dealer's parts department. This is the same
manual used by dealership technicians and
while it is highly technical it can be useful in
obtaining a better understanding of your car and
how it works.
G240A01A-AATPOWER STEERING HOSES
It is suggested that you check the power steer-
ing hose connections for fluid leakage at regular
intervals. The power steering hoses should be
replaced if there is severe surface cracking,
scuffing or worn spots. Deterioration of the hose
could cause premature failure. Recommended Fluid
Use PSF-3 type fluid
NOTE:Do not start the engine when the power
steering oil reservoir is empty.
G260A02A-AATREPLACING HEADLIGHT BULBS
Before attempting to replace a headlight bulb, be
sure the switch is turned to the "OFF" position.
The next paragraph shows how to reach head-
light bulbs so they may be changed. Be sure to
replace the burned-out bulb with one of the
same number and wattage rating.
!CAUTION:Keep the lamps out of contact with petro-
leum products such as oil, gasoline etc.
G270A03Y-AAT
Headlight Bulb
1. Allow the bulb to cool. Wear eye protection.
2. Always grasp the bulb by its plastic base,
avoid touching the glass.
G270A03Y
HEF-224
HEF-228
3. Turn the plastic cover counterclockwise
and remove it. High Beam
Low Beam
High BeamLow Beam
Turn signal Light

6- 22 DO-IT-YOURSELF MAINTENANCE
!
4. Disconnect the power cord from the bulb
base in the back of the headlight.
HEF-225
HEF-2291FJB5036HEF-226
HEF-230
WARNING:This halogen bulb contains gas under pres-
sure and if impacted could shatter, result-
ing in flying fragments. Always wear eye
protection when servicing the bulb. Protect
the bulb against abrasions or scratches
and against liquids when lighted. Turn the
bulb on only when installing in a headlight.
Replace the headlight if damaged or cracked.
Keep the bulb out of the reach of children
and dispose of the used bulb with care.
5. Push the bulb spring for removing the head-
light bulb.
High Beam
Low Beam
High Beam
Low Beam