2005 Hyundai Sonata engine

6
DO-IT-YOURSELF MAINTENANCE
26
2. Open the fuse box and examine each fuse.
Remove each fuse by pulling it toward you
(a small "fuse puller" tool is contained in the
relay and fuse box of the engine room to
simplify this operation).
3. Be sure to check all other fuses even if you
G200B02NF
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.
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.
!
G200B02L
GoodBurned outCAUTION:
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 6-39 for the fuse panel descrip-
tions.
G200B01NF-GATReplacing Accessory Fuse
G200B01NF-A
The fuse box for the lights and other electrical
accessories will be found on the left side of the
instrument panel. Inside the box you will find a
list showing the circuits protected by each fuse.
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.

6
DO-IT-YOURSELF MAINTENANCE
28
!
!
WARNING:Always read the following in-
structions carefully when han-
dling a battery.
Keep lighted cigarettes and all
other flames or sparks away from
the battery.
Hydrogen, which is a highly com-
bustible gas, is always present in
battery cells and may explode if
ignited.
Keep batteries out of the reach of
children because batteries con-
tain highly corrosive SULFURIC
ACID. Do not allow battery acid
to contact your skin, eyes, cloth-
ing or paint finish.
If any electrolyte gets into your
eyes, flush your eyes with clean
water for at least 15 minutes and
get immediate medical attention.
If possible, continue to apply
water with a sponge or cloth until
medical attention is received.If electrolyte gets on your skin,
thoroughly wash the contacted
area.
If you feel a pain or a burning
sensation, get medical attention
immediately.
Wear eye protection when charg-
ing or working near a battery.
Always provide ventilation when
working in an enclosed space.
o When lifting a plastic-cased battery, ex-
cessive pressure on the case may cause
battery acid to leak, resulting in personal
injury. Lift with a battery carrier or with
your hands on opposite corners.
o Never attempt to charge the battery when
the battery cables are connected.
o The electrical ignition system works with
high voltage.
Never touch these components with the
engine running or the ignition switched
on.
WARNING:
CHECKING ELECTRIC COOLING
FANS!
G220A01A-AAT
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 cooling 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.G220B01NF-GATChecking Engine Cooling FanThe engine cooling fan should come on auto-
matically if the engine coolant temperature is
high or whenever the air conditioning is in
operation.

6
DO-IT-YOURSELF MAINTENANCE
29
FOR MORE INFORMATION ABOUT
YOUR HYUNDAI
G240A01A-AATPOWER STEERING HOSESIt is suggested that you check the power steer-
ing hose connections for fluid leakage at those
intervals specified in the vehicle maintenance
schedule in Section 5.
The power steering hoses should be replaced
if there is severe surface cracking, pulling,
scuffing or worn spots. Deterioration of the hose
could cause premature failure.
POWER STEERING FLUID LEVELG230A03A-AAT
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.
Recommended Fluid
Use PSF-3 type fluidNOTE:Do not start the engine when the power
steering oil reservoir is empty.
G230A01NFG230A02NF
(2.4L)(3.3L)
G250A01A-AATIf 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.
The power steering fluid level should be checked
regularly. To check the power steering fluid
level, be sure the engine is "OFF", then check

6
DO-IT-YOURSELF MAINTENANCE
30
HEADLIGHT AIMING ADJUSTMENTG290A02O-AATBefore performing aiming adjustment, make
sure of the following.
1. Keep all tires inflated to the correct pressure.
2. Place the vehicle on level ground and press
the front bumper & rear bumper down sev-
eral times.
Place vehicle at a distance of 118 in. (3m)
from the test wall.
3. See that the vehicle is unloaded (except for
full levels of coolant, engine oil and fuel, and
spare tire, jack, and tools). Have the driver
or equivalent weight placed in driver's seat.
4. Clean the headlight lenses and turn on the
headlights (Low beam).
5. Open the hood.
G290A01NF-A
Vertical
aiming
!
6. Draw a vertical line (through the center of
each headlight beam pattern) and a horizon-
tal line (through the center of each headlight
beam pattern) on the aiming screen.
And then, draw a parallel line at 0.8 in. (21
mm) under the horizontal line.
7. Adjust each cut-off line of the low beam to the
parallel line with a phillips screwdriver -
VERTICAL AIMING.
WARNING:
Horizontal aiming should be adjusted by
an authorized Hyundai dealer.
G290B01NF-AATAdjustment After Headlight Assembly
Replacement
G260B01GK
L
W
H
H
Cut-off line
Ground line
"P"
Horizontal line
Vertical line
0.8 in.(21 mm)
If the vehicle has had front body repair and the
headlight assembly has been replaced, the
headlight aiming should be checked using the
aiming screen as shown in the illustration. Turn
on the headlight switch (Low Beam Position).
1. Adjust headlights so that main axis of light is
parallel to the center line of the body and is
aligned with point "P" shown in the illustration.
2. Dotted lines in the illustration show the center
of the headlights.

6
DO-IT-YOURSELF MAINTENANCE
31
SPECIFICATION:"H"
Horizontal center line of headlights from ground
: 26.73 in. (679mm)
"W"
Distance between each headlight center :
51.41 in. (1,306mm)
"L"
Distance between the headlights and the wall
that the lights are tested against : 118.11 in.
(3,000 mm)
REPLACEMENT OF LIGHT BULBSG260A01L-GATBefore attempting to replace a light bulb, be sure
the switch is turned to the "OFF" position.
The next paragraph shows how to reach the
light bulbs so they may be changed. Be sure to
replace the burned-out bulb with one of the
same number and wattage rating.
See page 6-38 for the wattage descriptions.
!
CAUTION:
o Keep the lights out of contact with pe-
troleum products, such as oil, gasoline,
etc.
o Be sure to replace the LED type equipped
bulbs with an assembly.
Replacement instructions:
1. Allow the bulb to cool. Wear eye protection.
2. Open the engine hood.
3. Always grasp the bulb by its plastic base,
avoid touching the glass.G270A01NF-AATHEADLIGHT, FRONT TURN SIGNAL
LIGHT AND FRONT FOG LIGHT
Headlight and Front Turn Signal Light
Headlight
(High beam)Headlight
(Low beam)
Turn signal light
(Front position light)
G260A01NF-A
Front Fog Light

6
DO-IT-YOURSELF MAINTENANCE
39
FUSE PANEL DESCRIPTIONG200C01NF-AATEngine Compartment
NOTE:Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time of printing. When you inspect the
fuse box on your vehicle, refer to the fuse box label.
HNF4005

6
DO-IT-YOURSELF MAINTENANCE
40
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
HORN
TAIL
ECU
IG1
DRL
FR FOG
A/CON
F/PUMP
DIODE
ATM
STOP
H/LP LO RH
S/ROOF
H/LP WASHER
H/LP HI
ECU
SNSR.3
SNSR.1
SNSR.2
B/UP
IGN COIL
ECU (IG1)
H/LP LO
ABS
PROTECTED COMPONENTS
ABS/ESC control module, Multipurpose check connector
ABS/ESC control module, Multipurpose check connector
Fuse 23, 24, 30, 31, 32, 33, 34, 35
Defogger relay
Blower relay
Power window relay, Fuse 16
Start relay, Ignition switch (IG2, START)
Engine control unit relay
Power connector 1/2, Fuse 21,22
Ignition switch (ACC, IG1)
Fusible Iink (ABS. 1, ABS. 2, RR HTD, BLOWER)
(Spare)
Horn relay
Tail light relay
PCM
(Spare)
Siren relay, DRL control module
Front fog light relay
A/C relay
Fuel pump relay
(Spare)
ATM control relay
Stop light relay
(Spare)
Sunroof control module
Headlight washer motor
Headlight relay (High)
(Spare)
Oxygen sensor, Fuel pump relay
Mass air flow sensor, Crankshaft/Camshaft position sensor, Oil control valve, SMATRA
A/C relay, Cooling fan relay, Injectors
Back up light switch, Pulse generator, Vehicle speed sensor
Ignition coils, Condenser
PCM
Headlight relay (Low)
ABS/ESC control module, Multipurpose check connector
ABS.1
ABS.2
I/P B+1
RR HTD
BLOWER
P/WDW
IGN.2
ECU RLY
I/P B+2
IGN.1
ALT
MDPSFUSE RATING
40A
20A
40A
40A
40A
40A
40A
30A
30A
30A
150A
100A
15A
20A
10A
10A
15A
15A
10A
20A
-
20A
15A
15A
15A
20A
20A
10A
10A
15A
15A
10A
20A
10A
20A
10A
DESCRIPTION
FUSIBLE
LINK
FUSE

7
EMISSION CONTROL SYSTEMS2
EMISSION CONTROL
SYSTEMS
H010B01A-AAT1. Crankcase Emission Control SystemThe positive crankcase ventilation system is
employed to prevent air pollution caused by
blow-by gases being emitted from the crank-
case. This system supplies fresh filtered air to
the crankcase through the air intake hose.
Inside the crankcase, the fresh air mixes with
blow-by gases, which then pass through the
PCV valve into the induction system.
CanisterFuel vapors generated inside the fuel tank are
absorbed and stored in the onboard canister.
When the engine is running, the fuel vapors
absorbed in the canister are drawn into the
surge tank through the purge control solenoid
valve.Purge Control Solenoid Valve (PCSV)The purge control solenoid valve is controlled
by the Engine Control Module (ECM); when the
engine coolant temperature is low during idling,
the PCSV closes so that evaporated fuel is not
taken into the engine. After the engine warms-
up during ordinary driving, the PCSV opens to
introduce evaporated fuel to the engine.H010D01A-AAT3. Exhaust Emission Control
SystemThe Exhaust Emission Control System is a
highly effective system which controls exhaust
emissions while maintaining good vehicle per-
formance.
H010A01NF-AATYour Hyundai is equipped with an emission
control system to meet all emission regulations.
There are three emission control systems which
are as follows.
(1) Crankcase emission control system
(2) Evaporative emission control system
(3) Exhaust emission control system
In order to assure the proper function of the
emission control systems, it is recommended
that you have your car inspected and main-
tained by an authorized Hyundai dealer in ac-
cordance with the maintenance schedule in this
manual.
Caution for the Inspection and Maintenance
Test (With Electronic Stability Control (ESC)
system)
o To prevent the vehicle from misfiring
during dynamometer testing, turn the
Electronic Stability Control (ESC) sys-
tem off by pressing the ESC switch.
o After dynamometer testing is completed,
turn the ESC system back on by pressing
the ESC switch again.
H010C01S-AAT2. Evaporative Emission Control (Includ-
ing ORVR: Onboard Refueling Vapor
Recovery) SystemThe Evaporative Emission Control System is
designed to prevent fuel vapors from escaping
into the atmosphere.
(The ORVR system is designed to allow the
vapors from the fuel tank to be loaded into a
canister while refueling at the gas station, pre-
venting the escape of fuel vapors into the
atmosphere.)