2004 Hyundai Sonata steering

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

6- 18 DO-IT-YOURSELF MAINTENANCE
G200A01Y-GATCHECKING AND REPLACING
FUSES
Replacing a Fusible Link
G200B01Y-GAT
Replacing Accessory Fuses
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
Good
V6
Power
steeringPower
steering Auto
tensioner
Generator
Generator
Eng.pulley Eng.pulleyCOMP COMPEng.coolant
0.30~0.48in.
0.24~0.35in.
DOHC
Open-
Replace

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 cooling 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

8- 4 CONSUMER INFORMATION & REPORTING SAFETY DEFECTS
!
!
I080A01A-AATTIRE TRACTION
Tire traction can be reduced if you drive on worn
tires, tires that are improperly inflated or on
slippery road surfaces. Tires should be re-
placed when tread wear indicators appear. To
reduce the possibility of losing control, slow
down whenever there is rain, snow or ice on the
road.
I070A01A-AATTIRE BALANCING
A tire that is out of balance may affect handling
and tire wear. The tires on your Hyundai were
balanced before the car was delivered but may
need balancing again during the years you own
the car.
Whenever a tire is dismounted for repair, it
should be rebalanced before being reinstalled
on the car.
I090A01A-AATWHEN TO REPLACE TIRESWARNING:
Driving on worn-out tires is dangerous!
Worn-out tires can cause loss of braking
effectiveness, steering control and trac-
tion. When replacing tires, never mix radial
and bias ply tires on the same car. If you
replace radial tires with bias-ply tires, they
must be installed in sets of four.
The original tires on your car have tread wear
indicators. The tread wear indicators appear
when the tread depth is 0.06 in. (1.6 mm). The
tire should be replaced when these appear as
a solid bar across two or more grooves of the
tread. Always replace your tires with those of
the recommended size. If you change wheels,
the new wheel's rim width and offset must meet
Hyundai specification.
WARNING:o Using tires and wheels of other than the
recommended sizes could cause un-
usual handling characteristics that could
cause death, serious injury, or property
damage.
o Wheels that do not meet Hyundai's di-
mensional specifications may fit poorly
and result in damage to the vehicle,
including broken wheel studs.
HGK248
0.06 in. (1.6 mm)
Wear indicator
!
Tires should be rotated every 7,500 miles
(12,000 km). If you notice that tires are wearing
unevenly between rotations, have the car
checked by a Hyundai dealer so the cause may
be corrected.
After rotating, adjust the tire pressures and be
sure to check the wheel nut tightness.
WARNING:o Do not use the temporary spare tire for
tire rotation.
o Do not mix bias ply and radial ply tires
under any circumstances. This may
cause unusual handling characteristics
that could result in death, serious injury,
or property damage.

9- 2 VEHICLE SPECIFICATIONS
J060A01Y-AAT
FUEL SYSTEM
J050A02Y-AATBRAKE
J040A03Y-AATELECTRICAL
J030A05Y-AATTIRE
J020A01Y-AAT
POWER STEERING
J010A03Y-AATMEASUREMENT
186.9 in. (4747 mm)
71.7 in. (1820 mm)
55.9 in. (1422 mm)
106.3 in. (2700 mm)
60.6 in. (1540 mm)
60.2 in. (1530 mm) Overall length
Overall width
Overall height (unladen)
Wheel base
Wheel tread
Front
Rear
Type
Wheel free play
Rack stroke
Oil pump typeRack and pinion
0 ~ 1.18 in. (0 ~ 30 mm)
5.75 in. (146 mm)
5.6 in. (142 mm)
Vane type
Tire pressure
30 (207)
60 (414)Tire
Standard
Spare
Item
Battery
Generator2.4L
MF 60AH (12V)2.7L (V6)
MF 68 AH (12V)
95A (13.5 V)
Dual hydraulic with brake booster
Solid disc
Disc type (with ABS)
Drum type (without ABS)
Cable operated on rear wheel Type
Front brake type
Rear brake type
Parking brake
17.2 us.gal (14.3 lmp.gal, 65 liter)
psi (kpa)
Size
P205/65R15
P205/60R16
T125/70D15, T125/70R15Fuel tank capacity 15" tire
16" tire

9- 4 VEHICLE SPECIFICATIONS
J080A09Y-AATLUBRICATION CHART
API SH, Hot Climate: SAE 20W-40, 20W-50 (ABOVE 32°F OR 0°C)
SG or Normal Climate:SAE 10W-30 10W-40, 10W-50 (ABOVE -10°F OR -23°C)
SG/CDCold Climate:SAE 5W-30 5W-40 (BELOW 100°F OR 38°C)
HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)
HYUNDAI GENUINE ATF, DIAMOND ATF SP-III or SK ATF SP-III
Ethylene glycol base for aluminum radiator
PSF-3 type fluid
DOT 3 or DOT 4 Equivalent Engine
TransaxleManual
Auto
Coolant
Power steering
Brakes and clutch fluid
Quantity (us.qts) (lmp.qts, liter)
2.2 (1.8, 2.1)
8.2 (6.9, 7.8)
0.95 (0.9)
As requiredItem
Oil & Coolant Standard2.4L 2.7L (V6)
Drain & refill;
Without oil filter :
4.2 (3.5, 4.0)
With oil filter :
4.5 (3.76, 4.3)Drain & refill;
Without oil filter :
4.45 (3.69, 4.2)
With oil filter :
4.77 (3.96, 4.5)
7.7 (6.4, 7.3)9.0 (7.6, 8.6)