2020 Hyundai SONATA (DN8A) G 2.5 GDI THETA III Service & Repair Manual

SONATA(DN8A) > 2020 > G 2.5 GDI THETA III > General - Important Safety Notice Proper service methods and repair procedures are essential for safe, reliable operation of all motor vehicles as well as personal safety of the operator. The service procedures and descriptions in this shop manual provide general directions for a service and repair. Procedure, techniques, tools, and parts for service including the skill of the technician vary. It is impossible to provide advice or caution as to each case in this manual. Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is not recommended by the vehicle manufacturer, must first assure thoroughly that neither their personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement part, service procedure, or tool they select. Reminds you to be especially careful in those areas where carelessness will cause death or serious injury. Reminds you to be especially careful in those areas where carelessness may cause death or serious injury. Reminds you to be especially careful in those areas where carelessness may cause personal injury. Gives you information that will prevent you from making errors that could damage the vehicle. Gives you added information that will help you complete a particular procedure. The following list contains some general WARNINGS that you should follow while working on a vehicle. • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires you to be under the vehicle. • Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. • Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in park unless instructed otherwise for a specific operation. • Place supporters against the front and rear surfaces of the tires to help prevent the vehicle from moving. • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide poisoning. • Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts. • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. • Do not smoke while working on a vehicle. • To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. • When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even though the ignition switch is in the OFF position. For this reason care should be taken to ensure that the radiator fan electric motor is completely disconnected when working under the hood and the engine is not running.

SONATA(DN8A) > 2020 > G 2.5 GDI THETA III > General - Identification Number Identification Number Description Vehicle Identification Number

1. World Manufacturer Identifier (WMI) - 5NP : Passenger vehicle 2. Vehicle line - E : DN8a 3. Model ＆ Series - F : Low grade (L) - G : Middle-Low grade (GL) - H : Middle grade (GLS, JSL, TAX) - J : Middle-High grade (HGS) - K : High grade (TOP) - L : Premium GL grade (PGL) 4.Body/Cabin type, Gross Vehicle Weight Rating [5NP] - 4 : 4DOOR 5. Restraint system, Brake system [5NP] - A : seat belt, FRT A/bag(Driver, Passenger), Side A/bag (1st row), Curtain A/bag (1st row, 2nd row) - B : seat belt, FRT A/bag(Driver, Passenger) - D : seat belt, FRT A/bag(Driver, Passenger), Side A/bag (1st row, 2nd row), Curtain A/bag (1st row, 2nd row) - E : seat belt, FRT A/bag(Driver) - F : seat belt, FRT A/bag(Driver, Passenger), Side A/bag (1st row) - J : seat belt, FRT A/bag(Driver, Passenger), Knee A/bag (Driver), Side A/bag (1st row, 2nd row), Curtain A/bag (1st row, 2nd row), Curtain A/bag (1st row, 2nd row) - L : seat belt, FRT A/bag(Driver, Passenger), Knee A/bag (Driver), Side A/bag (1st row), Curtain A/bag (1st row, 2nd row), Curtain A/bag (1st row, 2nd row) - N : seat belt 6. Engine type - A : Smartstream G 2.5 GDI - 2 : Smartstream G 1.6 T-GDI 7. Check digit or Driver’s side & Transmission - Check digit : 0 ~ 9, x 8. Model year - K : 2019, L : 2020, N : 2021, M : 2022... 9. Plant of production - A : Asan (Korea) - C : Cheonju (Korea) - U : Ulsan (Korea) - S : seosan 10. Vehicle production sequence number - 000001 - 999999 Paint Code Code Color W2B Geullowing Yellow

Y2E Peullaeing Red T2G Nocturne Gray Y2S Geullowing Silver R2T Simba Ringsilver NT2 Hampton Gray XB2 Oxford Blue M39 Midnight Black WC9 White Cream Engine Number 1. Engine fuel – G : Gasoline 2. Engine range – 4 : 4 cycle 4 cylinder 3 : Engine development order – F : Gamma engine – K : Theta engine 4. : Engine capacity – N : 2497cc (Smartstream G 2.5 GDI) – P : 1598cc (Smartstream G 1.6 T-GDI) 5. Model year – K : 2019, L : 2020, M : 2021, N : 2022 ... 6. Plant of production – A : Asan (Korea) – B : Beijing (China) – H : Hwasung (Korea) – K : Montgomery (U.S.A) – M : Chennai (India) – P : Poseung (Korea) – S : Sohari (Korea) – T : Izmit (Turkey) – U : Ulsan (Korea) – W : Shandong (China) – Z : Zilina (Slovakia) – 1 : Yancheng (China) 7. Engine production sequence number – 000001 - 999999 Transaxle Number Automatic (A8MF1)

1. Model - SA : A8MF1 2. Production year - K : 2019, L : 2020, M : 2021, N : 2022 ... 3. Gear ratio - F : 3.367 (Smartstream G 1.6 T-GDI) - D : 3.195 (Smartstream G 2.5 GDI) 4. Detailed classification - A : Smartstream G 1.6 T-GDI + ISG - B : Smartstream G 1.6 T-GDI + Non ISG - A : Smartstream G 2.5 GDI + ISG - A : Smartstream G 2.5 GDI + Non ISG 5. Plant classification - A : PTA - C : PTC - Plant 1 - D : PTC - Plant 2 - H : Hwasung (Korea) - M : Mexico - U : Ulsan - Plant 1 (Korea) - S : Ulsan - Plant 2 (Korea) - 2 : Powertech - Plant 2 (Korea) - 4 : Powertech - Plant 4 (Korea) 6. Transaxle production sequence number - 000001 - 999999

SONATA(DN8A) > 2020 > G 2.5 GDI THETA III > General - Warning and Caution Labels 1. Radiator cap caution 2. Fan caution 3. Battery caution Attention Srs Vehicle This car is equipped with a supplemental restraint system. To provide continedreliablity, certain elements of the supplemental restraint system shallbe serviced or replaced by authorized dealer ten years after vehicle label.For further information. see owner's manual. Side Air Bag This car is equipped with a side airbag system. To provide continued reliability,certain elements of the side airbag system shall be serviced or vehiclemanufacture date shown on certification label. For further information seeowner's manual. Battery Caution Label Describtion

Warning / Caution Label (Cont'd) A. Keep lighted cigarettes and all other flames or sparks away from the battery. B. Wear eye protection when charging or working near a battery. Always provide ventilation when working in an enclosed space. • When lifting a plastic-cased battery, excesive pressure on acid to leak resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. • Never attempt to change the battery when the battery cables are connected. • The electrical ignition system works with high voltage. Never touch these components with the engine running or the ignition switched on. C. Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow battery acid to contact your skin, eyes, clothing or paint finish. D. 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, throughly wash the contacted area. If you feel a pain or a burning sensation, get medical attention immediately. E. Always read the following instructions carefully when handing a battery. F. Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited. G. An improperly disposed battery can be harmful to the environment and human health.

Always confirm local regurations for battery disposal. Handling and Storage The Battery Battery Itself • Batteries should be stored in cool, dry (27 degrees Celsius) places and out of direct sunlight. • MF batteries are tightly sealed to prevent acid leakage. However, tilting the battery to an angle of 45 degrees can cause acid to leak through the vents on the sides. Therefore, batteries should always be stored in their upright positions. Prevent placing any aqueous or solid (i.e. conductors) bodies on top of the battery. • It is extremely dangerous to use tools, such as hammers, on the battery terminals when connecting cables to the mounted battery. Battery on Vehicle • When storing the vehicle for long periods of time, make sure to remove the memory fuse at junction box to prevent natural discharging. • Also, run the engine for battery charging within 1 month if the memory fuse wasn't removed from the start of vehicle storing. If the memory fuse was removed, run the engine for battery charging within 3 months from the start of vehicle storing. After reconnecting or recharging a discharged battery, the ESP OFF indicator may illuminate. In this case, turn the steering wheel half way to the left and right whilst the ignition switch is in the ON position. Then, restart the engine after the ignition is OFF. The EPS OFF indicator may turn OFF. If the EPS OFF indicator does not turn OFF, have the system checked refering to DTC. (Refer to the BR group.)

SONATA(DN8A) > 2020 > G 2.5 GDI THETA III > General - Lift and Support Points When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of the vehicle, the center of gravity may change and can cause the vehicle to tip forward on the hoist. • Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage area can assist with the weight distribution. • Use the same support points to support the vehicle on safety stands. 1. Place the lift blocks under the support points as shown in the illustration. 2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported. 3. Raise the hoist to full height to inspect the lift points for secure support.

SONATA(DN8A) > 2020 > G 2.5 GDI THETA III > General - Towing If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a vehicle : – The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle. – The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. The other two wheels remain on the ground. – The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension, and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged if this method of towing is attempted. If the vehicle cannot be transported by flat-bed, should be towed with the wheels of the drivig axle off the ground and do the following : Manual Transaxle • Release the parking brake. • Shift the Transaxle to neutral Automatic Transaxle • Release the parking brake. • Start the engine. • Shift to [D] position, then [N] position. • Turn off the engine. • The vehicle equipped with full-time 4WD should be only transported on a flat-bed. • The CVT vehicles should be only transported on a flat-bed or towed by wheel lift towing which the wheels of the driving axle are lifted off the ground. • Improper towing preparation will damage the transaxle. Follow the procedure above exactly. If you cannot shift the transaxle or start the engine(automatic transaxle), your vehicle must be transported on a flatbed. • It is the best to tow vehicle no farther than 30km (19miles), and keep the speed below 50km/h (30mph). (For the CVT and full-time 4WD (CVT/AT) vehicles, limit the towing distance and speed to 1.5km (1 mile) and 15km/h (10 mph).) • Trying to lift or tow your vehicle by the bumpers will cause serious damage to the vehicle. The bumpers are not designed to support the vehicle's weight. Front :

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2020 Hyundai SONATA (DN8A) G 2.5 GDI THETA III Service & Repair Manual

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