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Hyundai Sonata Workshop Manual (V6-3.3L (2006) ) OCR
Hyundai Sonata Workshop Manual (V6-3.3L (2006) ) OCR
Hyundai Sonata Workshop Manual (V6-3.3L (2006) ) OCR
com
Hyundai
Model
Sonata
V6-3.3L (2006)
Date
1st January 2018
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Antenna Control Module > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Relay >
Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
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Components Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 14
INSPECTION
1. Disconnect the negative (-) battery terminal. 2. Remove the junction box. 3. Check for continuity
between the terminals.
DOOR LOCK
1. There should be continuity between the No.12 and No.9 terminals in the I/P-D when power and
ground are connected to the No.12 terminal in the
DOOR UNLOCK
1. There should be continuity between the No.3 terminal in the I/P-E and No.9 terminal in the I/P-D
when power and ground are connected to the
2. There should be no continuity between the No.11 terminal in the I/P-E and No.9 terminal in the
I/P-D when power is disconnected.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module
> Component Information > Locations
SUMMARY: On certain passenger vehicles equipped with 3.3 liter engines and Electronic Stability
Control (ESC), The ESC may have been programmed to be oversensitive to the onset of
oversteering while driving on banked curves, causing inadvertent application of the front outside
brake when ESC activation may not be needed.
CONSEQUENCE: This may cause the vehicle to slow and may affect the path that the vehicle is
traveling. Brake application caused by inadvertent ESC activation may result in a crash.
REMEDY: Dealers will reprogram the ESC hydraulic electronic control unit. The recall began on
July 29, 2005. Owners should contact Hyundai at 1-800-633-5151.
NOTES: Hyundai recall No. 070. Customers can also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: >
05-01-007 > Jul > 05 > Recall - ESC ECU Reprogramming
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Group: CAMPAIGN
Number: 05-01-007
IMPORTANT:
IMPORTANT:
DESCRIPTION:
The Electronic Stability Control (ESC) of some 2006 Sonata vehicles equipped with 3.3 Liter
engines may be programmed to be too sensitive, causing inadvertent brake application on banked
curves.
To correct this condition, the ESC ECU may be reprogrammed using the Hi-Scan Pro as described
in this bulletin.
VEHICLES AFFECTED:
2. Be careful not to disconnect any cables connected to the vehicle or Hi-Scan Pro during
reprogramming.
WARNING:
^ When reprogramming the SONATA ESC ECU, the manual reprogramming mode [error mode] is
not available.
^ If ESC ECU reprogramming is interrupted during the "ESC ECU software data download" process
as a result of cable disconnection, power interruption or battery discharge, the ESC ECU must be
replaced.
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NOTE:
Verify that the vehicle was manufactured within the affected production date range and the
campaign is open per the DCS interactive screen.
1. Attach the Data Link Connector (DLC) cable to the Hi-Scan Pro main body and securely tighten
the two bolts.
2. Remove the system software card from the Hi-Scan Pro and insert the reprogramming software
card with the new ECU program into the Hi-Scan top slot.
3. Plug the DLC cable from the Hi-Scan Pro into the data link connector (16-pin connector) under
the instrument panel on the driver's side.
4. Turn the ignition switch to the ON position. (Do not start the engine).
6. Select option "61. SONATA ESP LOGIC IMPROVEMENT" and press ENTER.
7. Select option "01. SONATA ESP LOGIC [AUTO MODE]" and press ENTER.
8. Enter "1229" as the password for automatic reprogramming mode and press ENTER.
9. The Hi-Scan Pro will establish communication, check the ESC ECU ID and reprogram the ESC
ECU automatically.
CAUTION:
IF "ALREADY REPROGRAMMED. PRESS ANY KEY" is displayed on the Hi-Scan Pro screen in
step 9, exit the ESC ECU reprogramming procedure by pressing any key. The ESC ECU
reprogramming has previously been completed on this vehicle.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: >
05-01-007 > Jul > 05 > Recall - ESC ECU Reprogramming > Page 33
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10. Turn the ignition key OFF and ON. Press ENTER.
WARNING:
^ If the reprogramming is interrupted during the "BASIC AND FUNCTION DOWNLOAD" process,
repeat the reprogramming procedure again.
^ If the reprogramming is interrupted during the "ECU SW DATA DOWNLOAD" process, the ESC
ECU must be replaced.
NOTE:
^ The Hi-Scan Pro detects the current ESC ECU ID, assigns the new ESC ECU ID and displays
them on the Hi-Scan Pro screen.
^ Check the ESC ECU ID displayed on the Hi-Scan Pro screen to verify that the correct ESC ECU
software is being downloaded. Refer to the "ESC ECU SPECIFICATIONS TABLE" in this TSB.
11. Turn the ignition key OFF and ON. Press ENTER.
12. When the reprogramming is completed successfully, turn the ignition key to the OFF position
for about 20 seconds and start the engine to confirm proper operation of the vehicle.
13. Check for diagnostic trouble codes using the Hi-Scan Pro with the system software card and
erase any trouble codes.
3. "COMMUNICATION ERROR, PLEASE CHECK THE SYSTEM": In this case, the ESC ECU
must be replaced.
NOTE:
SUMMARY: On certain passenger vehicles equipped with 3.3 liter engines and Electronic Stability
Control (ESC), The ESC may have been programmed to be oversensitive to the onset of
oversteering while driving on banked curves, causing inadvertent application of the front outside
brake when ESC activation may not be needed.
CONSEQUENCE: This may cause the vehicle to slow and may affect the path that the vehicle is
traveling. Brake application caused by inadvertent ESC activation may result in a crash.
REMEDY: Dealers will reprogram the ESC hydraulic electronic control unit. The recall began on
July 29, 2005. Owners should contact Hyundai at 1-800-633-5151.
NOTES: Hyundai recall No. 070. Customers can also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 05-01-007 > Jul > 05 > Recall - ESC ECU Reprogramming
Electronic Brake Control Module: All Technical Service Bulletins Recall - ESC ECU
Reprogramming
Group: CAMPAIGN
Number: 05-01-007
IMPORTANT:
IMPORTANT:
DESCRIPTION:
The Electronic Stability Control (ESC) of some 2006 Sonata vehicles equipped with 3.3 Liter
engines may be programmed to be too sensitive, causing inadvertent brake application on banked
curves.
To correct this condition, the ESC ECU may be reprogrammed using the Hi-Scan Pro as described
in this bulletin.
VEHICLES AFFECTED:
2. Be careful not to disconnect any cables connected to the vehicle or Hi-Scan Pro during
reprogramming.
WARNING:
^ When reprogramming the SONATA ESC ECU, the manual reprogramming mode [error mode] is
not available.
^ If ESC ECU reprogramming is interrupted during the "ESC ECU software data download" process
as a result of cable disconnection, power interruption or battery discharge, the ESC ECU must be
replaced.
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NOTE:
Verify that the vehicle was manufactured within the affected production date range and the
campaign is open per the DCS interactive screen.
1. Attach the Data Link Connector (DLC) cable to the Hi-Scan Pro main body and securely tighten
the two bolts.
2. Remove the system software card from the Hi-Scan Pro and insert the reprogramming software
card with the new ECU program into the Hi-Scan top slot.
3. Plug the DLC cable from the Hi-Scan Pro into the data link connector (16-pin connector) under
the instrument panel on the driver's side.
4. Turn the ignition switch to the ON position. (Do not start the engine).
6. Select option "61. SONATA ESP LOGIC IMPROVEMENT" and press ENTER.
7. Select option "01. SONATA ESP LOGIC [AUTO MODE]" and press ENTER.
8. Enter "1229" as the password for automatic reprogramming mode and press ENTER.
9. The Hi-Scan Pro will establish communication, check the ESC ECU ID and reprogram the ESC
ECU automatically.
CAUTION:
IF "ALREADY REPROGRAMMED. PRESS ANY KEY" is displayed on the Hi-Scan Pro screen in
step 9, exit the ESC ECU reprogramming procedure by pressing any key. The ESC ECU
reprogramming has previously been completed on this vehicle.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 05-01-007 > Jul > 05 > Recall - ESC ECU Reprogramming > Page 44
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10. Turn the ignition key OFF and ON. Press ENTER.
WARNING:
^ If the reprogramming is interrupted during the "BASIC AND FUNCTION DOWNLOAD" process,
repeat the reprogramming procedure again.
^ If the reprogramming is interrupted during the "ECU SW DATA DOWNLOAD" process, the ESC
ECU must be replaced.
NOTE:
^ The Hi-Scan Pro detects the current ESC ECU ID, assigns the new ESC ECU ID and displays
them on the Hi-Scan Pro screen.
^ Check the ESC ECU ID displayed on the Hi-Scan Pro screen to verify that the correct ESC ECU
software is being downloaded. Refer to the "ESC ECU SPECIFICATIONS TABLE" in this TSB.
11. Turn the ignition key OFF and ON. Press ENTER.
12. When the reprogramming is completed successfully, turn the ignition key to the OFF position
for about 20 seconds and start the engine to confirm proper operation of the vehicle.
13. Check for diagnostic trouble codes using the Hi-Scan Pro with the system software card and
erase any trouble codes.
3. "COMMUNICATION ERROR, PLEASE CHECK THE SYSTEM": In this case, the ESC ECU
must be replaced.
NOTE:
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 49
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 50
1. Disconnect the brake tube from the HECU by unlocking the nuts counterclockwise with a
spanner. 2. Lift up the vehicle.
3. Disconnect the connector (A) from the HECU. 4. Remove the two HEW brake mounting bolts
(B), and then disassemble the HECU with the bracket.
CAUTION: 1. Never attempt to disassemble the HECU. 2. The HECU must be transported and
stored in upright position and with sealed ports. 3. Never shock to the HECU.
5. Remove the two HECU mounting nuts and washer, and then remove the bracket.
INSTALLATION
1. Installation is the reverse of removal. 2. Tighten the HECU mounting bolts and brake tube nuts to
the specified torque.
Tightening torque HECU mounting nut 5.88 - 9.8 Nm (0.6 - 1 kgf.m 4.36 - 7.27 ft. lbs.) HECU
bracket mounting bolt: 16.66 - 25.48 Nm (1.7 - 2.6 kgf.m 12.36 - 18.9 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control
Module > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions
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Radiator Cooling Fan Control Module: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 59
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 62
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 63
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 67
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 69
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 71
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 73
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Locations
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Radiator Cooling Fan Motor Relay: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 79
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
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tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 82
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 83
l
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 84
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 85
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 87
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 88
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 89
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 90
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 91
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 92
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 93
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations
Passenger unparlmant
rainy but {Eh-Hr Inky-FL! mm]
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Diagram Information and Instructions
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Blower Motor Relay: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 100
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 103
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 104
l
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 105
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 106
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 108
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Blower Motor Relay: Testing and Inspection
INSPECTION
1. Disconnect the negative (-) battery terminal. 2. Remove the passenger compartment relay box.
3. There should be continuity between the No.9 in the I/P-K and No.15 in the I/P-A terminals when
power and ground are connected to the No.16 in
the I/P-D and No.13 I/P-B terminals in the passenger compartment relay box.
4. There should be no continuity between the No.9 in the I/P-K and No.15 in the I/P-A terminals
when power is disconnected. 5. If the blower motor voltage does not operate properly, substitute
with a known-good blower relay and check for proper operation. 6. If the problem is corrected,
replace the blower relay.
MANUAL TYPE
1. There should be continuity between the No.3 and No.4 terminals when power and ground are
connected to the No.1 and No.2 terminals.
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2. There should be no continuity between the No.3 and No.4 terminals when power is
disconnected.
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Information > Locations > A/C Control Module (Auto)
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Information > Locations > A/C Control Module (Auto) > Page 121
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Control Module HVAC: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Information > Diagrams > Diagram Information and Instructions > Page 128
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Information > Diagrams > Diagram Information and Instructions > Page 129
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Panel Illumination Control Module: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 144
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
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tha color uf 1h: calm uf
backgrmfl‘rd Stripe
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unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 147
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 148
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 149
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 150
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 152
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 153
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 154
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 155
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 156
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 157
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 158
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Testing and Inspection
INSPECTION
1. The daytime running light unit (A) is integrated in the junction box.
2. Check that the light operate according to the following timing chart. 3. If the daytime running light
is not operated well, inspect the connector and terminals to be sure they are all making good
contact.
If the terminals are bent, loose or corroded, repair them as necessary, and recheck the system. If
the terminals look OK, go to step 4.
4. Make these input tests at the connector by using ETM If any test indicates a problem, find and
correct the cause, then recheck the system.
If all the input tests prove OK, the junction box must be faulty; replace it.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay
> Component Information > Locations
E. FIJI pump M
2+ Han-i lump why {High} 1'. Whur rally
3. Stan rally E. Alr nurtliiminn relay
4-. EfiE—I curtrd relay 9. Frunt flag mlay
5. NT rainy 1D. Hum Inlay
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay
> Component Information > Locations > Page 166
1. Pull out the front fog lamp (A) relay from the engine compartment relay box. 2. Check for
continuity between terminals. There should be continuity between the No.i and No2 terminals when
power and ground are connected to
the No.3 and No.4 terminals.
3. There should be no continuity between the No.1 and No.2 terminals when power is
disconnected.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations
E. FIJI pump M
2+ Han-i lump why {High} 1'. Whur rally
3. Stan rally E. Alr nurtliiminn relay
4-. EfiE—I curtrd relay 9. Frunt flag mlay
5. NT rainy 1D. Hum Inlay
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 170
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3. There should be no continuity between the No.1 and No.4 terminals when power is
disconnected.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Page 177
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Engine Compartment Junction Block Circuit Details
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Page 178
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Engine Compartment Junction Block View
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Page 179
Passenger Compartment Relay Box View
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Diagram Information and Instructions
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Relay Box: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Diagram Information and Instructions > Page 182
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Diagram Information and Instructions > Page 185
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Diagram Information and Instructions > Page 186
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Diagram Information and Instructions > Page 187
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Diagram Information and Instructions > Page 188
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Diagram Information and Instructions > Page 190
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 191
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Engine Compartment Junction Block View
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Passenger Compartment Relay Box View
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INSPECTION
2. There should be no continuity between the No.1 and No.2 terminals when power is
disconnected.
1. There should be continuity between the No.1 and No.2 terminals when power and ground are
connected to the No.3 and No.5 terminals.
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2. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
1. There should be continuity between the No.1 and No.4 terminals when power and ground are
connected to the No.2 and No.3 terminals.
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2. There should be no continuity between the No.1 and No.4 terminals when power is
disconnected.
2. There should be continuity between the No.1 and No.5 terminals when power is disconnected.
FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse
capacities for each circuit correct? 3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why
the fuse blew first and completely eliminate the problem before installing a new fuse.
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Relay Box: Testing and Inspection Relay Box (Passenger Compartment)
FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse
capacities for each circuit correct? 3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why
the fuse blew first and completely eliminate the problem before installing a new fuse.
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EPEGAIFIBATIOHE Ema:
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Specifications
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Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
3
Symbols Part 1
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Instructions > Page 230
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Instructions > Page 231
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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- Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 232
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BCM Module Input Signal Test (Part 2)
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- Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 235
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Connector Views: The Connector Pin Out Views for connectors shown on these diagrams can be
found on the Connector Pin Out images that follow
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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- Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 239
most sets of system diagrams.
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- Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 240
DESCRIPTION
Body control module (A) receives various input switch signals controlling time and alarm functions
for the intermittent wiper timer, washer timer, rear defogger timer, seat belt reminder, delayed out
room lamp, central door lock, ignition key reminder, power window timer, door warning, tail lamp
auto cut, crash door unlock, auto door lock, 2-turn unlock, ignition key hole illumination control and
keyless entry & burglar alarm.
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Inspection and Diagnostic Overview
LH‘I'UHDAI VEHICLE DIAGNOSIS Tl
MDDEL : EDMTA D5
D1. ALBUMS TRANSAJILE
D2. AMI—LUCK BRAKE E‘I'ETEM
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TAIL LAMP 5W
AUTD LIGHT 5W
1. The body control module can diagnose by using the diagnosis tool more quickly.
The BCM communicates with the diagnosis tool and then reads the input/output value and drives
the actuator.
2. To diagnose the BCM function, select the menu of model and body control module.
3. To consult the present input/out value of BCM, "02. INPUT/OUTPUT MONITORING". It provides
information of BCM input/output conditions
of power supply, turn signal/brake lamp, headlamp, door, locks, outside mirror, wiper, auto-light
and transmitters etc.
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- Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 243
L HYUNDAI 1I:.I|'EHII.".I:LE DIAGNOSIS
MODEL : SDIIIATA US
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4. To perform compulsory operation on BCM input factors, select "03. ACTUATION TEST"
USER OPTION MODE
The BCM ofters 3 items user option mode for a user convenience (Auto door lock, door key burglar
alarm, door lock state inform horn)
- It is able to set up the enable or disable of AUTO DOOR LOCK function or AUTO DOOR LOCK
operation vehicle speed when using it.
- It is able to set up the enable or disable of enter the burglar alarm mode when using door lock by
the key.
- It is able to set up the enable or disable of horn inform function when using door lock by the key or
RKE.
1. .
3. Select option "USER OPTION" and press ENTER. 4. Select option "AUTO DOOR LOCK
STATUS by using the direction button(up/down).
5. Select the parameter by using the direction button(left/right) and press ENTER to save it.
(Disable / Enable).
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Inspection and Diagnostic Overview > Page 245
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1. With the tail lamp switched ON, if the ignition is switched OFF and the driver's door opened, the
tail lamp should be automatically turned
OFF.
2. With the ignition switch ON, if the driver's door is opened and the ignition is switched to OFF, the
tail lamp should be automatically turned
OFF.
3. When the tail lamp is cut automatically and the tail lamp switch is turned OFF and ON, the tail
lamp illuminates and auto cut function is
cancelled.
4. When the tail lamp is cut automatically and the ignition key is inserted, the tail lamp illuminates
and auto cut function is canceled.
1. Ignition keyhole illumination is turned ON when the driver or passenger door is opened. 2. The
"ON" state for ignition keyhole illumination is delayed 10 seconds when the door is closed as in
Step 1). 3. Ignition keyhole illumination is turned off if the ignition switch is turned ON as in Step 1)
& 2).
4. Ignition keyhole illumination is turned off if ARM state is entered. See Steps 1) & 2).
1. When the first door (driver, or assist or 4doors) is opened, room amp is turned on. 2. When the
door is closed, the room lamp is faded out for 2 seconds after there is on for 30 seconds. 3.
Regardless of ignition ON/OFF in door open state, room lamp output is ON. 4. When remote
control unlock is received, room lamp is turned on for 30 seconds
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Inspection and Diagnostic Overview > Page 246
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received, then room lamp is again on for 30 sec.
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6. CENTRAL DOOR LOCK function is not performed during or after CRASH UNLOCK signal
output.
But, CENTRAL DOOR LOCK function is performed normally if CRASH UNLOCK function is reset
after IG OFF
6. 2-TURN UNLOCK
1. All door unlock signals are output for T2 if driver door key unlock switch is turned ON within T1
after changing driver door key unlock switch
from OFF to ON (mechanically, driver door key unlock switch is unlocked and BCM signal is not
output). (All door unlock signals are output even within T1 after RKE UNLOCK signal is received.)
2. Driver door unlock signal is output for T2 when RKE UNLOCK signal is received. But, all door
unlock signals are output for T2 if RKE
UNLOCK signal is received within T1. (All door unlock signals are output for T2 even when RKE
UNLOCK signal in T1 is received after changing driver door key unlock switch from OFF to ON.
1. This does not activate when vehicle speed is less than 5km/h. 2. Lock signal is output if vehicle
speed is 5km/h or more for at least is under ALT" L" ON, IGN SW = ON. But, lock signal is not
output if all
3. Lock signal is output 3 times as Max ((2) is ignored) if either one door is unlocked after lock
signal output in (2).(1s cycle) But, door, which is
4. Relevant door is fail if the state is unlock after 3-time output. 5. Lock signal is output once if the
fail door is unlocked again after the door is locked.
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6. Lock signal is output once if locked doors, which are lock state after lock signal output in (2),are
unlocked again.
But, lock signal is output once for the relevant door even when unlock state continues after lock
signal output.
8. Auto door lock function is not performed when crash unlock condition is met
1. This function is not performed when vehicle speed is 3km/h or more. 2. DRIVER UNLOCK signal
is output for is after 0.5s from when the state becomes KEY IN SW = IN & DRIVER DOOR = OPEN
& DRIVER
3. ALL DOOR UNLOCK signals are output for is after 0.5s from when the state becomes KEY IN
SW = IN & ASSIST DOOR = OPEN &
4. UNLOCK signal is output 3times as Max (Is-output is excluded) in case LOCK state is held even
when UNLOCK signal is output for Is in
1. If the key is in the key cylinder and the driver door is opened, the buzzer is sounded (period: 0.7
sec., duty rate: 50%).
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Inspection and Diagnostic Overview > Page 249
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2. If the ignition key is removed, or the door is closed, the buzzer is switched OFF immediately.
10. WINDSHIELD DEICER & DEFOGGER TIMER
1. Once ALT "L" is ON, if the defogger is switched ON, the defogger will stay ON for 20 minutes
duration.
2. If defogger switch is pressed again (see Step 1), or if ignition is switched OFF the defogger will
shut OFF.
1. When the ignition is switched OFF, power window output remains ON for 30 seconds and then
turns OFF 2. Related to Step 1), if the driver's door or assist door is opened, window power output
is turned OFF immediately.
3. When the driver's door or assist door is opened, the power window relay output is turned OFF
immediately.
- If washer switch is turned on, wiper output is ON after 0.3 sec. (T5)
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Inspection and Diagnostic Overview > Page 250
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- If washer switch is turned OFF, wiper output is OFF after 3.8 sec. (T6)
2. If the washer switch is turned OFF within 0.6 sec. (T2), the wiper will remain ON for up to 0.7
sec. (T3) from the moment that washer switch
is turned OFF
1. With the ignition switch ON, if the intermittent wiper switch is turned on, wiper output is ON
according to the setting.
2. When the intermittent wiper switch is ON, if the ignition switch is turned ON, wiper output is ON.
1. Warning lamp lights every 0.6sec and buzzer sounds every 1sec for 6 sec when IGN is ON
under unfastened seat belt.
(Warning lamp continues to light for 6 sec if seat belt is fastened within 6 sec) 30 seconds time
count starts at ALT "L" ON under this state.(30 seconds time count starts after 6 sec. if ALT" L" is
ON within initial 6 sec)
2. Buzzer stops and the warning lamp is turned OFF when IGN is turned OFF within 6 seconds
output. 3. Buzzer stops and the warning lamp is turned OFF and 30 seconds time count also stops
when seat belt is fastened after IGN ON. 4. If unfastened seat belt state continues after 60 seconds
time count from ALT" ON, the warning lamp flashes and buzzer sounds 11 times in 30
sec-cycle (6 sec ON/ 24 sec OFF) after 30 sec from ALT "L" ON.
5. Warning lamp & buzzer are turned OFF when IGN is OFF or seat belt is fastened during (4). 6.
Operation in (1) is performed when seat belt is unfastened again under ALT "L" ON and fastened
seat belt. 7. Operation in (4) is performed when ALT "L" is turned ON again after turning OFF under
unfastened seat belt.
1. Warning lamp lights continuously every 0.6 sec when IGN is turned ON under unfastened seat
belt. 2. Warning lamp is turned OFF when IGN is turned OFF within 0.6sec. 3. When IGN is ON
under unfastened seat belt, the warning lamp lights. The lamp continues to light for remaining time
of 6 sec when seat belt is
fastened within 6 sec. The lamp is OFF if seat belt is fastened after 6 sec.
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Inspection and Diagnostic Overview > Page 251
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4. After 6 sec from IGN ON, warning lamp continues to flash when S/BELT is unfastened and stop
immediately when S/BELT is fastened.
16. AUTO LIGHT CONTROL
1. Auto light sensor value is always read at IGN ON. 2. Light is turned ON after 2 sec ± 0.2sec
when auto light sensor value is same as light ON input value. 3. Light is turned OFF after2 sec ±
0.2sec when sensor value is same as light OFF input value. 4. Tail lamp and head lamp are turned
ON when sensor value is same as tail lamp ON input value. 5. Light ON value of sensor is based
on the below table. 6. Head lamp signal is output when head lamp switch is ON. 7. After head lamp
is turned OFF, head lamp signal output is kept if head lamp ON luminance condition is met at auto
light switch ON. 8. After head lamp is turned OFF, head lamp signal output is immediately stopped
if head lamp OFF luminance condition is met at auto light
switch ON.
9. After head lamp is turned OFF, head lamp signal output is immediately stopped at tail switch
signal input. 10. After head lamp is turned OFF, head lamp signal output is stopped after 0.7 sec. if
there is no input of auto light switch or tail switch. (Shall be
11. Head lamp signal output is stopped when switch position is changed from AUTO to head lamp
switch during head lamp ON with auto light.
12. The condition of head lamp ON/OFF is same as the one of tail lamp ON/OFF at auto light
switch ON. Light ON value of the input sensor is
REPLACEMENT
1. Disconnect the negative (-) battery terminal. 2. Remove the floor console.
3. Remove the keyless antenna cable and body control module (A) after loosening 2 nuts. 4.
Installation is the reverse of removal.
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- Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations
Detail
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- Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 256
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638
Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P2135/P0638
Group: FUEL SYSTEM
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 265
From:
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
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Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 266
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 270
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Etienne-ertiunitt
NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
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SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
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CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
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Tm: I: pun-gran for updltlng EDI.
Darn llll‘llfll a m [In-gm. durum flu upflh.
I] I 3
5%
ROM ID Reading...
4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
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I«'Iehuirflle 51W Management
m J || .‘U-r'lll' r.41.':‘-1:'II'IT.'-; 3 ."ir'II'IIHI". ;. Fr.;.r.-...-t:n;..n.-. r-.—.rm.-.|
- " : ' r lii'w M.=|n:|r]r-r'r::-" 'C-L' |.|I'.:I':|I‘5IJE
ECU Upgrade I
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Data Tmaiment
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(NOTICE:-
IF TD” WT,
THE SYSTEM DUES MDT WORK.
6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
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ECU Upgrade
-| Curr-I'll: Hmlfl-
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update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
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CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
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Number 10-FL-002
Subject ECM UPDATE - MIL ON DTC P161B - HARD START/ROUGH IDLE COLD
DESCRIPTION:
This bulletin provides information related to the ECM Update (software) of the applicable listed
vehicles below some of which may experience a malfunction indicator lamp illuminated with the
following system-related DTC:
^ P161B: (ECM Torque Calculation Performance). Vehicle may exhibit hard start and rough idle at
cold start. This is a cold start issue related to
NOTE:
DTC P1295, P2105 and/or P2106 may also set together with P161B after vehicle was running in
limited power limp home mode.
This update will also resolve the following system related DTC issues that may occur to some
vehicles, but not result in drivability issues:
NOTE:
To verify the vehicle is affected, be sure to check the version of the vehicle's engine control unit
ROM ID with reference to the ROM ID Information Table shown below before attempting to update
the control unit software.
Refer to below tables for Santa Fe and Sonata as to applicable ROM-ID's for this TSB.
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WHY Hint! FOIGH] 3.3L 1Ml'l'll'l H-ll'li - Upclltl “In! #155:
Modal
Yur EDI! PIN
Previous
EIIHHEJ‘SIASHIBB
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m lmw-acm EHIHEE‘EEASBJHBF
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CHHETSEASBJHEP
CHIHJTSEABHJIAF
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m-mmv SeneteINF} 3.3!. with K-Ilne - Update event #153:
am I m '3 I
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Service Procedure
CAUTION:
state for reliable update results. The ECM Update procedure contains a check to ensure that
battery voltage is above 12 volts to allow the procedure to occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 20% or more charge
remaining. Charge the laptop battery with the AC
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, A/C, blower, radio, seat warmer, defroster, etc.)
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
2. Enter the vehicle information by pressing the VIN Auto Detect button, entering the vehicle's VIN
or selecting the vehicle model, model year, engine/fuel type and ENGINE as the system and then
click OK.
3. Select ECU Upgrade on the initial screen after entering the vehicle information.
4. Select Auto Mode then ENGINE in the left ECU Upgrade column.
7. After the Current ROM ID is displayed, select the Upgrade Event that appears in the pulldown
list it will be either of these as listed below:
NOTE:
Choose a later Event # if it appears in the Auto Mode pull-down list as it will contain fixes for other
more recent issues as well as for the issues identified by this TSB.
8. After clicking the Upgrade button, read Information then click OK.
9. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine for 10 minutes or longer to ensure
an adequate battery charge state for reliable update results.
10. Update will begin and the progress of the update will appear on the bar graph.
11. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
m 335331“ W
g ECUUpgrada
ltuntnlllflllfll I 'Lfllflflflfllfll
+- "PEI-d. Eflm |151cm 33 amen: HEHTEH Lam: IIIIPHEWEHEHT - cm
|= Ealflct system=
L- = Select aystam =
CH 3.3 fl'ElH‘I' HUN IHHD I 39110-33555
CH 3.3 flQlIl‘I' IIIIHEI I 3911fl-3G51 5
-l1'|'ll'lll .. |:..h II-L ..:..l'! l . -
13. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
CAUTION:
^ Manual update should be performed only when automatic update fails after the ECM update had
begun showing the progress bar.
^ Pull out the ECM fuse from the engine compartment junction box or disconnect the battery
negative cable for at least one minute to reset the control
unit before performing manual upgrade. Turn the ignition key back to the ON position.
^ If neither of the above works disconnect the connectors from the ECM for 10 minutes and try
again.
1. Within the ECU Upgrade screen, select Manual Mode in the left column, then select the
appropriate upgrade event# from the below table. Select the appropriate control unit part number
with reference to the ROM ID Information Table and click OK.
CAUTION:
Be sure to select NON IMMO part number for the correct vehicle as Santa Fe and Sonata vehicles
in USA do not have immobilizer.
2. Enter the appropriate password from the tables below and click OK.
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IIEHU PAEWDHD
GM 3 3 “DH IMMD 39113-3333":I
3. 3 ”DH IMMD: 39113—36551 3531
airman
MENU PAESWDHD
NF 3.3 DEW HUN ll'w'll'ul'IIIZTJl : 33113-3C33I3 33311
NF 3.3 MW HDNIMMD :39113—3C?E1 3TH
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
4. Update will begin and the progress of the update will appear on the bar graph.
5. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
7. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the upgrade and
clear the DTC (s) present.
CAUTION:
There are 2 ROM-ID of the 2008MY Sonata ROM-ID table that require VIN write after the reflash.
DTC P0630 may set for a No VIN error. Perform the VIN write and clear the DTC after.
Hut-ELM HDIIEL
199%11105 [EF] Emma
Ems-10 {HF} Samta
milk-DE [5M1- Samar“:
ram-HI] {EM} 5m F:
Human!) {HG} xfimsm
2m1~flfi {ED} Elflnlrra
11103-413 (GK) 11mm:
2mg [Ilufl Tmsun
m {TE} Am
lam—us [Emmuumge
Engine Control Module: Customer Interest A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's
Set
Group TRANSAXLE
Number 09-AT-018
Subject ATA SOLENOID DIAGNOSTIC TROUBLE CODES P0740, P0741, P0742, P0743, P0746,
P0748, P0750, P0755, P0760, P0765, P0770
This TSB supersedes TSB# 05-40-006 to change the test procedure (Step 5) and add additional
models.
DESCRIPTION:
Incorrect operation of the transaxle solenoids may result in the following symptoms:
^ Diagnostic Trouble Codes P0740, P0741, P0742, P0743, P0746, P0748, P0750, P0755, P0760,
P0765 or P0770 set
NOTE:
Do NOT replace the transaxle for solenoid codes listed as open/short. Instead, follow the repair
procedure shown below.
APPLICABLE VEHICLES:
NOTE:
Refer to TSB 09-AT-011 for 2007~10 (HD) Elantra Sedan and (FD)
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PARTS INFORMATION
REPAIR PROCEDURE:
1. Using a GDS, check for DTC in both the "Engine" and "Automatic Transaxle" menus. Record the
DTC and description.
^ Vehicle
^ "Actuation Test"
^ Press the "Start" button and listen for a solenoid sound and "Success" indication.
^ Fail: go to Step 3
^ Success: the wiring between the PCM/TCM currently has no open or short circuits. Go to Step 4.
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J .I -'-JI l . l ' . l l l III'l-IIII-I luli I n Mr-
in!!!El" IHII'
:‘I
9 5 ‘ l-‘r_.:._r_lli'..IJJ { bill-jfflrfu 4hr flui'q'u 'I'sgu'nr ‘ flu?" -
2-. Fall: 1:: 'I' I'm-1:: T i m [EC-l
l Efim l M
I] fill. EWDFF.‘F'FIIHEE m
Giltlm'l TI'EJlIT‘IIEIfit mm - -
Data. Trualm-arrl
In SpEEHDI‘l I Test .-_._.,
MODEL Harman PM
4530131955:
Refer to parts catalog
45305—330“
NOTE:
This test confirms the wiring harness currently does not have an open or short circuit. It does not
confirm the proper functioning of the solenoids under all conditions of heat and vibration or a
solenoid with an intermittent open/short condition.
3. If Step 2 shows an inoperative solenoid, visually check the wiring harness between the TCM and
transaxle for a damaged wire or a short circuit to ground. Disconnect the connectors to the
solenoids at the transaxle and the PCM/TCM and check for a bent pin or a pin not fully inserted into
the connector. If so, repair or replace the ECM control harness, P/N 914xx-xxxxx.
4. Check the harness inside the transaxle oil pan for a short circuit to ground. Replace the harness
if damage is found or if three or more solenoid DTC are found in Step 1. (Refer to TSB#04-40-015
for replacement instructions).
5. Refer to the DTC recorded in Step 1 and follow the repair procedure shown below:
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DTD REPAIR PRDEEDURE
I F0740. F0740. F0740. F0700. F0700. F0700.
F0705. F0770. F0740 at Ram-ea the related Inlanaidl
I F0743 {ll' F0740. F0741 0r F0742 Illfl let}
I P0740 [I70 duhh auntral syntarn pru-hllm} manlyr Clint “Ennina” and I*‘l'nlnla.'«:la" rnanu far 070:
I P0741 [WC duhh stuck all] ulnmlqI I ll' OTC P0330 nr P0720: Fallmu pmdura Hall.
I P0742 [1'10 dutch stuck an] ::Iln|3,I I lfng 0T0 P0330 ur P0720: Raplaua tha haul-:0-
[If nu afllar anlanuid 0T0 all)
P0330 (Crankshaft pualllnn annular rnalhncllnn} I check hill!!! and unnnaabara tn CHIP aanlnr
and ECWTGM. If DH. replace CHIP IIIIIDI'.
F0720 {GHF mam - 000“ almalt}
I fill!!! lullnnid DTG.
P1520 - TGlll MIL maul: algnal
Damned:
P0700 - TCM MIL mutual: algnal
0'0
LEE
RED
VFE
BITE REPAIR
10. Refer to the DTC recorded in Step 1 and replace the related solenoid according to the diagram
shown. Tighten the bolts to 4-5 lb.ft (50-70 kg.cm). Go to step 11.
11. Apply Permatex Ultra Gray Sealer or Hyundai Ultra Gray Gasket Sealer, P/N 00231-13800 to
the valve body cover and reinstall the cover. Tighten the bolts to 6-7 lb.ft (80-100 kg.cm).
12. Reinstall the radiator hoses and add ethylene glycol coolant to the radiator and overflow bottle.
Adjust the level according to the appropriate shop manual, "EM" section.
13. Add approximately five quarts of Hyundai SPIII ATF and check the level with the engine idling
in Neutral. Refer to TSB 06-40-016 and adjust the ATF level when the ATF is at normal operating
temperature (70-80°C, 158-176°F).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 297
14. Clear the codes and test drive the vehicle for two driving cycles (two key-on to key-off driving
cycles, including 1-2-3-4 upshifts and 4-3-2-1 downshifts). If the DTC returns, perform the repairs
shown above.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441 Set
Number 09-FL-008
DESCRIPTION:
Some 2006-2007 Sonata (NF) 3.3L / Azera (TG) 3.8L, and 2007 Santa Fe (CM) 3.3L vehicles may
experience malfunction indicator lamp illumination for DTC P0441 (Evaporative Emission System -
Incorrect Purge Flow).
NOTE:
APPLICABLE VEHICLES: ^ 2006-2007 Sonata (NF) 3.3L ^ 2006-2007 Azera (TG) 3.8L ^ 2007
Santa Fe (CM) 3.3L
NOTE:
To verify the vehicle is affected, be sure to check the version of the vehicle's engine control unit
ROM ID with reference to the ROM ID Information Table mentioned below before attempting to
update the control unit software.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441 Set > Page 302
HUM ID
5cm H" auug new
CHENSTSEAfiHEEB I CME-NSTEIASESM
CHEN33*51A5'553AA Il' CHEHETEIAEEEIEEA
39110 _ CHENETSEAE'EEECAJ CHENETSZAS'EEM
313530 CHENE‘SEAEEEEEC .Ir CMEHETEEAEET'IM ( : m
CHEN33*52A55T1HA I CHEHETSEASBT‘IDA
CHEN33* 5355?1 F A } CHEN33*52A5571HA
CMEHH'fiEflEEflW
3511a _ CHBHETSEASEHCAI CMEHETSEASEHEA
ECEE'I CHEHEE'EEASET‘I GA! CHBHET SW'LJA CHEHWEIASW
CHEH3T52A55335A
EL'II PM "a" In
FEEVIDLIE HEW
TGSHBB‘MEAEED'IAA! 155"arunssmaa
Tasuaruznssnzu nssuaruznssm BE
39110-302111 Tafinawmznssacn HasnawmznssEznn
1'55"33*M2A55E3AA ,. Tssuaamzmsaam
TGEHH‘MEASESBBE I TGEHETHEASEEHBC Tfifllflfl IEAEEEEIA
3911Ila-3cm Taanwunsaauan : TGEHEE‘HIASEHAA
TGEHWMIAEEH BE I TGEHSE‘MEAEJEHEE
Tsfinaruznsanm
Ham ur- cun: ! or "A“! al- THE mum rnr Hlfl'UIIE Imus:
HF 3.3L 5:! 351111- _____
:Il 3.3L 31111!!a UPGRADE M Inn-I r Hula-m nun In taut In: NH cm
TE 3.3L {III-IJIIE] cur-mm Em Pill]:
Perform the ECM update when DTC P0441 occurs. If the condition exists after the ECM update,
perform EVAP system diagnostics related to DTC P0441 prior to replacing the Purge Control
Solenoid Valve (PCSV).
WARRANTY INFORMATION
Service Procedure
SERVICE PROCEDURE:
CAUTION:
^ Please ensure the following items during the control unit update.
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage for
days, run the engine to ensure an adequate battery charge
^ Turn off all lamps (Do not leave head lamp switch in auto mode) and all accessories (including
heater, A/C, blower, radio, seat warmer, defroster, etc.)
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
A: Diagnostic Terminal
B: VCI [Vehicle Cnmmunicatiun Intatfaca)
C: USB {Uniuaraal Serial Bus] Cable
D: i a r Supply Cable
E: DLC Gable
NOTE:
If attempting to perform the update with the power supply cable disconnected from the diagnostic
terminal, make certain that the diagnostic terminal is charged enough for the update. If not, the
update may fail in progress. Therefore, it is strongly recommended to connect the power supply
cable to the diagnostic terminal during the update procedure.
2. Connect the USB cable between the VCI and the diagnostic terminal.
NOTE:
When performing the update using the GDS, wireless communication between the VCI and the
diagnostic terminal is NOT available. Therefore, be sure to connect the USB cable between the
VCI and the diagnostic terminal.
3. Connect the 16-pin DLC cable from the VCI into the vehicle's 16-pin connector under the driver
side instrument panel.
4. Turn on the VCI and diagnostic terminal with the ignition key in the ON position.
NOTE:
Upgrada Hunt
135. NF 3.3 P2135 AND P0533 DTC LOGIC - [DEHUTM‘I’]
126. CM 2.?!3.3 132135 AND P0533 13TC LDGIC - K LINE
130. TB 3.3 F2135 AND F0533 DTC LEE-IE - Fri-LINE
2. Enter the vehicle information by pressing the VIN Auto Detect button, entering the vehicle's VIN
or selecting the vehicle model, model year, engine/fuel type and ENGINE as the system and then
click OK.
3. Select ECU Upgrade on the initial screen after entering the vehicle information.
4. Select Auto Mode then ENGINE in the left ECU Upgrade column.
8. After clicking the Upgrade button, read Information then click OK.
9. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
10. Update will begin and the progress of the update will appear on the bar graph.
11. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
13. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
CAUTION:
^ Pull out the ECM fuse from the engine compartment junction box or disconnect the battery
negative cable to reset the control unit before performing
manual update.
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441 Set > Page 305
2. Within the ECU Upgrade screen, select Manual Mode in the left column, then select appropriate
upgrade event. Select the appropriate control unit part number with reference to the ROM ID
Information Table and click OK.
3. Enter the appropriate password from the table above and then click OK.
4. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
5. Update will begin and the progress of the update will appear on the bar graph.
6. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
Number: 08-AT-003
Model: 1999~ SONATA, 2001~06 ELANTRA, 2001~ SANTA FE & XG, 2003~ TIBURON, 2005~
TUCSON, 2006~ AZERA, 2007~ ENTOURAGE
This TSB supersedes TSB 07-40-010 to correct the labor time for OP Code 95440RP0 and
95440PQ0.
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed upshift or downshift,
follow the Diagnostic Procedure shown below.
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue with the diagnosis.
4. Attach the GDS and check for Diagnostic Trouble Codes in both the "Engine" and "Automatic
Transaxle" menu. If DTC's are found, repair according to the appropriate TSB or shop manual.
NOTE:
"Current Data"
^ "Shift position"
^ "Vehicle speed"
^ Select "PC Record" (on left of screen) and save the file.
"Items List" (top right of screen) and select: "Vehicle speed" and "Shift position".
PCM/TCM DIAGNOSIS:
Confirm the PCM or TCM commanded each gear: 1, 2, 3, 4 and 5 (if equipped): ^
If so, go to pages 3~6 and evaluate the upshift diagnosis for the related shift.
If not, exchange a PCM or TCM from a properly operating vehicle and test again to determine if the
PCM or TCM commanded each gear:
^ If the condition is not improved, go to page 3~6 and evaluate the upshift performance.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Underdrive Solenoid Duty"
and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 1-2 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The 2nd solenoid elapsed time is important; the shape of the graph is not.
['r':IL"Ir_II1II
I.'.l‘.l 'l'IH':I'I I
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "Underdrive Solenoid Duty", "Overdrive
Solenoid Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the OD solenoid elapsed time at the top right of the screen. If the 2-3 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive values":
NOTE:
The OD solenoid elapsed time is important; the shape of the graph is not.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Overdrive Solenoid
Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 3-4 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
. I
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Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "Reduction Solenoid Duty", Low-Reverse
Solenoid Duty and "Shift Position".
^
Select the "+" or "-" button to choose 0.7 sec./Div or less.
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the LR solenoid elapsed time at the top right of the screen. If the 4-5 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION:
NOTE:
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 08-AT-003 > May > 08 > A/T - Harsh/Delayed Upshift/Downshift > Page 313
Warranty Claim requires input of DTC codes on all claims using Hi-Scan or GDS operations. If no
DTC code is identified by the Hi-scan or GDS, enter P0000 as a Scan Tool Test Code on the
Warranty Claim and attach printout from the Hi-scan or GDS to the Repair Order.
NOTE:
Printouts must be attached to all Repair Orders. Repair Orders without attached printouts are
subject to chargeback.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement
mm
ATF at nen'nel eperetfng temperature {158-212°F, FBI-1ETC}
‘ —
Engine Control Module: Customer Interest A/T - Harsh/Delayed Reverse or Drive Engagement
Group: TRANSAXLE
Number: 07-40-009-1
Models: 1999 - SONATA 2001-06 - ELANTRA 2001 - SANTA FE & XG 2003 - TIBURON 2005 -
TUCSON 2006 - AZERA 2007 - ENTOURAGE
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed shift into Drive or
Reverse, follow the Diagnostic Procedure shown below:
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
2. Perform the adaptive learning by shifting from Neutral to Reverse and Drive, stopping in each
gear for 5 seconds. Repeat 10 times.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue the diagnosis.
4. Check that idle speed is within specification. If not, inspect according to the appropriate shop
manual, "Fuel System Section".
5. Check the engine and transaxle mounting brackets and roll support brackets. If necessary,
replace the mounts.
6. Attach the GDS and check for Diagnostic Trouble Codes in both the "ENGINE" and
"AUTOMATIC TRANSAXLE" menus. If DTC are found, repair according to the appropriate TSB or
shop manual.
7. Attach the GDS and select "AUTOMATIC TRANSAXLE" menu, "CURRENT DATA" menu and
"FLUID TEMPERATURE SENSOR". Confirm the oil temperature sensor operates correctly as
shown. If not, inspect the oil temperature sensor according to TSB 04-40-016 or appropriate shop
manual.
8. Select "CURRENT DATA" and "TPS". Open and close the throttle and confirm the TPS
increases and decreases smoothly between approximately 0 - 100% duty.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 318
' ; . . . _ I __ I .__..::.fi.-—I—r'_ ‘ i - F .‘ _
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9. Attach the GDS and select VIN and "A/T" "Current Data" and then select "Shift Position", "LR
Solenoid Duty" and "Underdrive Solenoid Duty" as shown.
10. Start the engine and move the shift lever between Neutral, Drive and Reverse, stopping 3-5
seconds in each gear.
11. Select "Record shown" at the top right of the screen. GDS will record up to 10 minutes data
prior to selecting "Record".
12. Select "PC Record" (top left of screen), then save file.
13. Select "Flight Record" and "Data Review", select the vehicle and open the file.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 319
. _'=' 1':I::!|-'iF¢I-"
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Data, 1mm:
Flight Rfinnrd IIJIJ'I-
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14. Select "Items List" (top right of screen), then select "Shift Position", "LR Solenoid Duty" and
"Underdrive Solenoid Duty".
16. Move the cursor to the start of the shift and "Left click".
17. Move the cursor to the end of the shift and "Right Click".
18. Read the Low & Reverse solenoid engagement time on the top right of the screen. If the P-R
shift requires more than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle
and follow TSB 06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
20. Select "Items List" (top right of screen), then select "Shift Position LR Solenoid Duty" and
"Underdrive Solenoid Duty".
22. Move the cursor to the start of the shift and "Left click".
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 320
1 . -. - - ‘Ru...|.|.l".l.-l-I.- I._J.-'l' —-_FI'TF'-
B nlc Incipient-III
cTc Anny-II: —
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Flight Retard PM
IJWTJRIIT’? '-
ufiflfcfif"m5‘-Z'
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NDTE: Warranty Claim requlrea Input cf DTG ccclea an all claims ualng Hl-Scan
cr GEE cperatiene. H' nc DTL": cede ie identified by the Hi-ecan er GDS,
enter Fflflflfl aa a Scan cl Teat Code on the Warranty Claim and attach
plintcut frcrn the Hi-acan er GDS tn the Repair Grder.
NDTE: Frintcuta must be attached to all Repair Drdars. Repalr Orders wlthcut
attached printcuts are subject tc chargeback.
23. Move the cursor to the end of the shift and "Right Click".
24. Read the UD engagement time on the top right of the screen. If the P-D shift requires more
than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The UD solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 11-AT-008 > Apr > 11 > A/T - TCM/ECM Adaptive Value
Rest/Relearn Procedure
: ; »
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Engine Control Module: All Technical Service Bulletins A/T - TCM/ECM Adaptive Value
Rest/Relearn Procedure
Group:AUTOMATIC TRANSAXLE
Number: 11-AT-008
Model: ALL
This bulletin supersedes TSB 10-AT-Oil to include 2011~ Elantra, 2012~ Accent and Genesis
Sedan.
After replacing a transaxle or reprogramming the PCM/TCM, follow this procedure to reset and
relearn the adaptive learning to improve shift quality.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
arm: jam- m
1.1mm
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[Gene-II ASL. Equal MEL, and Gene-II Camp-e 3.0L wlfl'u 2F Inn-mlnlun].
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
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6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified TPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 11-AT-008 > Apr > 11 > A/T - TCM/ECM Adaptive Value
Rest/Relearn Procedure > Page 329
Adaptive learning occurs only within the ATF temperature ranges shown.
WARRANTY INFORMATION:
“Mum m m F m
System
Sula-ct Sygtnm SEI acted System
“mamaHQ —
§@@@@@g
_ 7 —..:a__l—l-
Engine Control Module: All Technical Service Bulletins A/T Controls - Resetting PCM/TCM
Adaptive Values
Number: 10-AT-Oil
Model: ALL
Subject
This bulletin supersedes TSB 09-AT-002-1 to include Equus and Sonata HEV
CAUTION:
After replacing a transaxle or reprogramming the PCM/TCM, to improve the shift quality condition,
follow this procedure to reset and relearn the adaptive learning.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
HDTE: * Clear BAH Laarnahla sum: only If Mmhatrunlu {valva may: I: filfihfll’lflifl mam Inufllfl mun
[El-fillil 1.6L. Equus LEI. and GHI-flil- Gnupl 3.5L with 2F trim-ninth}.
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
m m m w w m fl n
' 1 ? t 'l-5 I."
6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified IPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Technical Service Bulletins for Engine Control Module: > 10-AT-011 > Aug > 10 > A/T Controls - Resetting PCM/TCM
Adaptive Values > Page 337
NOTE:
Adaptive learning occurs only within the ATF temperature ranges shown:
WARRANTY INFORMATION:
Normal warranty applies
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P2135/P0638
Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's
P2135/P0638
Group: FUEL SYSTEM
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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Frant
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
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P2135/P0638 > Page 343
mm ID
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NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
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SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
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P2135/P0638 > Page 350
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
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P2135/P0638 > Page 351
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4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
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P2135/P0638 > Page 352
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6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
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P2135/P0638 > Page 353
ECU Upgrade
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update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
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P2135/P0638 > Page 354
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
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Number 10-FL-002
Subject ECM UPDATE - MIL ON DTC P161B - HARD START/ROUGH IDLE COLD
DESCRIPTION:
This bulletin provides information related to the ECM Update (software) of the applicable listed
vehicles below some of which may experience a malfunction indicator lamp illuminated with the
following system-related DTC:
^ P161B: (ECM Torque Calculation Performance). Vehicle may exhibit hard start and rough idle at
cold start. This is a cold start issue related to
NOTE:
DTC P1295, P2105 and/or P2106 may also set together with P161B after vehicle was running in
limited power limp home mode.
This update will also resolve the following system related DTC issues that may occur to some
vehicles, but not result in drivability issues:
NOTE:
To verify the vehicle is affected, be sure to check the version of the vehicle's engine control unit
ROM ID with reference to the ROM ID Information Table shown below before attempting to update
the control unit software.
Refer to below tables for Santa Fe and Sonata as to applicable ROM-ID's for this TSB.
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DTCs/Rough Idle > Page 361
WHY Hint! FOIGH] 3.3L 1Ml'l'll'l H-ll'li - Upclltl “In! #155:
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m lmw-acm EHIHEE‘EEASBJHBF
CHMETEEASBJHCF M l fl m
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CHIHJTSEABHJIAF
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Technical Service Bulletins for Engine Control Module: > 10-FL-002 > Jan > 10 > Engine Controls - MIL ON/Multiple
DTCs/Rough Idle > Page 362
m-mmv SeneteINF} 3.3!. with K-Ilne - Update event #153:
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Service Procedure
CAUTION:
state for reliable update results. The ECM Update procedure contains a check to ensure that
battery voltage is above 12 volts to allow the procedure to occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 20% or more charge
remaining. Charge the laptop battery with the AC
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, A/C, blower, radio, seat warmer, defroster, etc.)
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
2. Enter the vehicle information by pressing the VIN Auto Detect button, entering the vehicle's VIN
or selecting the vehicle model, model year, engine/fuel type and ENGINE as the system and then
click OK.
3. Select ECU Upgrade on the initial screen after entering the vehicle information.
4. Select Auto Mode then ENGINE in the left ECU Upgrade column.
7. After the Current ROM ID is displayed, select the Upgrade Event that appears in the pulldown
list it will be either of these as listed below:
NOTE:
Choose a later Event # if it appears in the Auto Mode pull-down list as it will contain fixes for other
more recent issues as well as for the issues identified by this TSB.
8. After clicking the Upgrade button, read Information then click OK.
9. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine for 10 minutes or longer to ensure
an adequate battery charge state for reliable update results.
10. Update will begin and the progress of the update will appear on the bar graph.
11. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
Q ECU Upgrada
lEunlmflflllfll I ill-IRWIN
+- "PEI-d. Eflm |151cm 33 amen: HEHTEH Lam: IIIIPHEWEHEHT - cm
|= Ealflct system=
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CH 3.3 fl'ElH‘I' HUN IHHD I 39110-33555
CH 3.3 flQlIl‘I' IIIIHEI I 3911fl-3G51 5
lill'll'l I: .. |:..h II-L . . : . . l ' ! l . -
13. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
CAUTION:
^ Manual update should be performed only when automatic update fails after the ECM update had
begun showing the progress bar.
^ Pull out the ECM fuse from the engine compartment junction box or disconnect the battery
negative cable for at least one minute to reset the control
unit before performing manual upgrade. Turn the ignition key back to the ON position.
^ If neither of the above works disconnect the connectors from the ECM for 10 minutes and try
again.
1. Within the ECU Upgrade screen, select Manual Mode in the left column, then select the
appropriate upgrade event# from the below table. Select the appropriate control unit part number
with reference to the ROM ID Information Table and click OK.
CAUTION:
Be sure to select NON IMMO part number for the correct vehicle as Santa Fe and Sonata vehicles
in USA do not have immobilizer.
2. Enter the appropriate password from the tables below and click OK.
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Technical Service Bulletins for Engine Control Module: > 10-FL-002 > Jan > 10 > Engine Controls - MIL ON/Multiple
DTCs/Rough Idle > Page 366
IIEHU PAEWDHD
GM 3 3 “DH IMMD 39113-3333":I
3. 3 ”DH IMMD: 39113—36551 3531
.-;II* 1 . 1 1 v .
airman
MENU PAESWDHD
NF 3.3 DEW HUN ll'w'll'ul'IIIZTJl : 33113-3C33I3 33311
NF 3.3 MW HDNIMMD :39113—3C?E1 3TH
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
4. Update will begin and the progress of the update will appear on the bar graph.
5. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
7. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the upgrade and
clear the DTC (s) present.
CAUTION:
There are 2 ROM-ID of the 2008MY Sonata ROM-ID table that require VIN write after the reflash.
DTC P0630 may set for a No VIN error. Perform the VIN write and clear the DTC after.
Hut-ELM HDIIEL
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Engine Control Module: All Technical Service Bulletins A/T - MIL ON/Failsafe Mode/Multiple
Solenoid DTC's Set
Group TRANSAXLE
Number 09-AT-018
Subject ATA SOLENOID DIAGNOSTIC TROUBLE CODES P0740, P0741, P0742, P0743, P0746,
P0748, P0750, P0755, P0760, P0765, P0770
This TSB supersedes TSB# 05-40-006 to change the test procedure (Step 5) and add additional
models.
DESCRIPTION:
Incorrect operation of the transaxle solenoids may result in the following symptoms:
^ Diagnostic Trouble Codes P0740, P0741, P0742, P0743, P0746, P0748, P0750, P0755, P0760,
P0765 or P0770 set
NOTE:
Do NOT replace the transaxle for solenoid codes listed as open/short. Instead, follow the repair
procedure shown below.
APPLICABLE VEHICLES:
NOTE:
Refer to TSB 09-AT-011 for 2007~10 (HD) Elantra Sedan and (FD)
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Technical Service Bulletins for Engine Control Module: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple
Solenoid DTC's Set > Page 371
PARTS INFORMATION
REPAIR PROCEDURE:
1. Using a GDS, check for DTC in both the "Engine" and "Automatic Transaxle" menus. Record the
DTC and description.
^ Vehicle
^ "Actuation Test"
^ Press the "Start" button and listen for a solenoid sound and "Success" indication.
^ Fail: go to Step 3
^ Success: the wiring between the PCM/TCM currently has no open or short circuits. Go to Step 4.
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple
Solenoid DTC's Set > Page 372
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Refer to parts catalog
45305—330“
NOTE:
This test confirms the wiring harness currently does not have an open or short circuit. It does not
confirm the proper functioning of the solenoids under all conditions of heat and vibration or a
solenoid with an intermittent open/short condition.
3. If Step 2 shows an inoperative solenoid, visually check the wiring harness between the TCM and
transaxle for a damaged wire or a short circuit to ground. Disconnect the connectors to the
solenoids at the transaxle and the PCM/TCM and check for a bent pin or a pin not fully inserted into
the connector. If so, repair or replace the ECM control harness, P/N 914xx-xxxxx.
4. Check the harness inside the transaxle oil pan for a short circuit to ground. Replace the harness
if damage is found or if three or more solenoid DTC are found in Step 1. (Refer to TSB#04-40-015
for replacement instructions).
5. Refer to the DTC recorded in Step 1 and follow the repair procedure shown below:
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple
Solenoid DTC's Set > Page 373
DTD REPAIR PRDEEDURE
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10. Refer to the DTC recorded in Step 1 and replace the related solenoid according to the diagram
shown. Tighten the bolts to 4-5 lb.ft (50-70 kg.cm). Go to step 11.
11. Apply Permatex Ultra Gray Sealer or Hyundai Ultra Gray Gasket Sealer, P/N 00231-13800 to
the valve body cover and reinstall the cover. Tighten the bolts to 6-7 lb.ft (80-100 kg.cm).
12. Reinstall the radiator hoses and add ethylene glycol coolant to the radiator and overflow bottle.
Adjust the level according to the appropriate shop manual, "EM" section.
13. Add approximately five quarts of Hyundai SPIII ATF and check the level with the engine idling
in Neutral. Refer to TSB 06-40-016 and adjust the ATF level when the ATF is at normal operating
temperature (70-80°C, 158-176°F).
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple
Solenoid DTC's Set > Page 374
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50505351550515 5255051013 533331030 0.3 3:55
14. Clear the codes and test drive the vehicle for two driving cycles (two key-on to key-off driving
cycles, including 1-2-3-4 upshifts and 4-3-2-1 downshifts). If the DTC returns, perform the repairs
shown above.
WARRANTY INFORMATION
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441
Set
Number 09-FL-008
DESCRIPTION:
Some 2006-2007 Sonata (NF) 3.3L / Azera (TG) 3.8L, and 2007 Santa Fe (CM) 3.3L vehicles may
experience malfunction indicator lamp illumination for DTC P0441 (Evaporative Emission System -
Incorrect Purge Flow).
NOTE:
APPLICABLE VEHICLES: ^ 2006-2007 Sonata (NF) 3.3L ^ 2006-2007 Azera (TG) 3.8L ^ 2007
Santa Fe (CM) 3.3L
NOTE:
To verify the vehicle is affected, be sure to check the version of the vehicle's engine control unit
ROM ID with reference to the ROM ID Information Table mentioned below before attempting to
update the control unit software.
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441
Set > Page 379
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Perform the ECM update when DTC P0441 occurs. If the condition exists after the ECM update,
perform EVAP system diagnostics related to DTC P0441 prior to replacing the Purge Control
Solenoid Valve (PCSV).
WARRANTY INFORMATION
Service Procedure
SERVICE PROCEDURE:
CAUTION:
^ Please ensure the following items during the control unit update.
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage for
days, run the engine to ensure an adequate battery charge
^ Turn off all lamps (Do not leave head lamp switch in auto mode) and all accessories (including
heater, A/C, blower, radio, seat warmer, defroster, etc.)
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
A: Diagnostic Terminal
B: VCI [Vehicle Cnmmunicatiun Intatfaca)
C: USB {Uniuaraal Serial Bus] Cable
D: i a r Supply Cable
E: DLC Gable
^ Do not turn off the ignition switch during update.
NOTE:
If attempting to perform the update with the power supply cable disconnected from the diagnostic
terminal, make certain that the diagnostic terminal is charged enough for the update. If not, the
update may fail in progress. Therefore, it is strongly recommended to connect the power supply
cable to the diagnostic terminal during the update procedure.
2. Connect the USB cable between the VCI and the diagnostic terminal.
NOTE:
When performing the update using the GDS, wireless communication between the VCI and the
diagnostic terminal is NOT available. Therefore, be sure to connect the USB cable between the
VCI and the diagnostic terminal.
3. Connect the 16-pin DLC cable from the VCI into the vehicle's 16-pin connector under the driver
side instrument panel.
4. Turn on the VCI and diagnostic terminal with the ignition key in the ON position.
NOTE:
Upgrade Hunt
135. NF 3.3 P2135 AND PDEBB DTC LOGIC - [DE~DTMY)
125. CM 2.?!3.3 132135 AND P0533 ETC LDGIC - HE LINE
130. TB 3.3 F2135 AND F0633 DTC LEE-IE - Fri-LINE
2. Enter the vehicle information by pressing the VIN Auto Detect button, entering the vehicle's VIN
or selecting the vehicle model, model year, engine/fuel type and ENGINE as the system and then
click OK.
3. Select ECU Upgrade on the initial screen after entering the vehicle information.
4. Select Auto Mode then ENGINE in the left ECU Upgrade column.
8. After clicking the Upgrade button, read Information then click OK.
9. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
10. Update will begin and the progress of the update will appear on the bar graph.
11. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
13. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
CAUTION:
^ Pull out the ECM fuse from the engine compartment junction box or disconnect the battery
negative cable to reset the control unit before performing
manual update.
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Technical Service Bulletins for Engine Control Module: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441
Set > Page 382
2. Within the ECU Upgrade screen, select Manual Mode in the left column, then select appropriate
upgrade event. Select the appropriate control unit part number with reference to the ROM ID
Information Table and click OK.
3. Enter the appropriate password from the table above and then click OK.
4. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
5. Update will begin and the progress of the update will appear on the bar graph.
6. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
Number: 08-AT-003
Model: 1999~ SONATA, 2001~06 ELANTRA, 2001~ SANTA FE & XG, 2003~ TIBURON, 2005~
TUCSON, 2006~ AZERA, 2007~ ENTOURAGE
This TSB supersedes TSB 07-40-010 to correct the labor time for OP Code 95440RP0 and
95440PQ0.
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed upshift or downshift,
follow the Diagnostic Procedure shown below.
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue with the diagnosis.
4. Attach the GDS and check for Diagnostic Trouble Codes in both the "Engine" and "Automatic
Transaxle" menu. If DTC's are found, repair according to the appropriate TSB or shop manual.
NOTE:
"Current Data"
^ "Shift position"
^ "Vehicle speed"
^ Select "PC Record" (on left of screen) and save the file.
"Items List" (top right of screen) and select: "Vehicle speed" and "Shift position".
PCM/TCM DIAGNOSIS:
Confirm the PCM or TCM commanded each gear: 1, 2, 3, 4 and 5 (if equipped): ^
If so, go to pages 3~6 and evaluate the upshift diagnosis for the related shift.
If not, exchange a PCM or TCM from a properly operating vehicle and test again to determine if the
PCM or TCM commanded each gear:
^ If the condition is not improved, go to page 3~6 and evaluate the upshift performance.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Underdrive Solenoid Duty"
and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 1-2 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The 2nd solenoid elapsed time is important; the shape of the graph is not.
['r':IL"Ir_II1II
I.'.l‘.l 'l'IH':I'I I
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "Underdrive Solenoid Duty", "Overdrive
Solenoid Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the OD solenoid elapsed time at the top right of the screen. If the 2-3 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive values":
NOTE:
The OD solenoid elapsed time is important; the shape of the graph is not.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Overdrive Solenoid
Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 3-4 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
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Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "Reduction Solenoid Duty", Low-Reverse
Solenoid Duty and "Shift Position".
^
Select the "+" or "-" button to choose 0.7 sec./Div or less.
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the LR solenoid elapsed time at the top right of the screen. If the 4-5 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION:
NOTE:
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 08-AT-003 > May > 08 > A/T - Harsh/Delayed Upshift/Downshift >
Page 390
Warranty Claim requires input of DTC codes on all claims using Hi-Scan or GDS operations. If no
DTC code is identified by the Hi-scan or GDS, enter P0000 as a Scan Tool Test Code on the
Warranty Claim and attach printout from the Hi-scan or GDS to the Repair Order.
NOTE:
Printouts must be attached to all Repair Orders. Repair Orders without attached printouts are
subject to chargeback.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive
Engagement
mm
ATF at nen'nel eperetfng temperature {158-212°F, FBI-1ETC}
‘ —
Engine Control Module: All Technical Service Bulletins A/T - Harsh/Delayed Reverse or Drive
Engagement
Group: TRANSAXLE
Number: 07-40-009-1
Models: 1999 - SONATA 2001-06 - ELANTRA 2001 - SANTA FE & XG 2003 - TIBURON 2005 -
TUCSON 2006 - AZERA 2007 - ENTOURAGE
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed shift into Drive or
Reverse, follow the Diagnostic Procedure shown below:
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
2. Perform the adaptive learning by shifting from Neutral to Reverse and Drive, stopping in each
gear for 5 seconds. Repeat 10 times.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue the diagnosis.
4. Check that idle speed is within specification. If not, inspect according to the appropriate shop
manual, "Fuel System Section".
5. Check the engine and transaxle mounting brackets and roll support brackets. If necessary,
replace the mounts.
6. Attach the GDS and check for Diagnostic Trouble Codes in both the "ENGINE" and
"AUTOMATIC TRANSAXLE" menus. If DTC are found, repair according to the appropriate TSB or
shop manual.
7. Attach the GDS and select "AUTOMATIC TRANSAXLE" menu, "CURRENT DATA" menu and
"FLUID TEMPERATURE SENSOR". Confirm the oil temperature sensor operates correctly as
shown. If not, inspect the oil temperature sensor according to TSB 04-40-016 or appropriate shop
manual.
8. Select "CURRENT DATA" and "TPS". Open and close the throttle and confirm the TPS
increases and decreases smoothly between approximately 0 - 100% duty.
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive
Engagement > Page 395
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9. Attach the GDS and select VIN and "A/T" "Current Data" and then select "Shift Position", "LR
Solenoid Duty" and "Underdrive Solenoid Duty" as shown.
10. Start the engine and move the shift lever between Neutral, Drive and Reverse, stopping 3-5
seconds in each gear.
11. Select "Record shown" at the top right of the screen. GDS will record up to 10 minutes data
prior to selecting "Record".
12. Select "PC Record" (top left of screen), then save file.
13. Select "Flight Record" and "Data Review", select the vehicle and open the file.
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive
Engagement > Page 396
Data, 1mm:
Flight Rfinnrd IIJIJ'I-
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14. Select "Items List" (top right of screen), then select "Shift Position", "LR Solenoid Duty" and
"Underdrive Solenoid Duty".
16. Move the cursor to the start of the shift and "Left click".
17. Move the cursor to the end of the shift and "Right Click".
18. Read the Low & Reverse solenoid engagement time on the top right of the screen. If the P-R
shift requires more than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle
and follow TSB 06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
MEASURE PARK TO DRIVE ENGAGEMENT TIME:
19. Select "Flight Record" and "Data Review", select the vehicle and open the file.
20. Select "Items List" (top right of screen), then select "Shift Position LR Solenoid Duty" and
"Underdrive Solenoid Duty".
22. Move the cursor to the start of the shift and "Left click".
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- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive
Engagement > Page 397
1 . -. - - ‘Ru...|.|.l".l.-l-I.- I._J.-'l' —-_FI'TF'-
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cr GEE cperatiene. H' nc DTL": cede ie identified by the Hi-ecan er GDS,
enter Fflflflfl aa a Scan cl Teat Code on the Warranty Claim and attach
plintcut frcrn the Hi-acan er GDS tn the Repair Grder.
NDTE: Frintcuta must be attached to all Repair Drdars. Repalr Orders wlthcut
attached printcuts are subject tc chargeback.
23. Move the cursor to the end of the shift and "Right Click".
24. Read the UD engagement time on the top right of the screen. If the P-D shift requires more
than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The UD solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION
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Technical Service Bulletins for Engine Control Module: > tnt1660906-03 > Sep > 06 > A/T, Engine Controls - ECM/TCM
Reset/Relearn Procedure
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EHTUURI'IEE BBL HM. EIIIE M‘l'r-
Engine Control Module: All Technical Service Bulletins A/T, Engine Controls - ECM/TCM
Reset/Relearn Procedure
MODEL: All
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This article provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. After the
following repairs have been completed, the PCM/TCM adaptive values must be reset in order to
provide optimum shift quality:
Adaptive values must be reset using procedure # 1 or # 2 according to model and model year (MY)
as shown below.
VEHICLES AFFECTED:
^ All
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P."
^ Select vehicle
press "ENTER"
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
NOTE:
Adaptive learning does not occur below the ATF temperature range shown.
WARRANTY INFORMATION:
4 —
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Engine Control Module: All Technical Service Bulletins Engine Controls - ECU Reprogramming
Procedure
Reprogramming
This issue of TechNet Times focuses on reprogramming. In the current Hyundai service
environment, reprogramming can be accomplished with the Hi-Scan Pro or Hyundai's new Global
Diagnostic System (GDS). We begin here with an overview of the process of reprogramming the
ECU as performed using the GDS on a 2006 Azera that experiences a 1-2 shift hesitation under
wide open throttle operation when cold. As with most GDS features, you must select the model,
year and system in order to get started. You can manually enter the information by selecting
drop-down box options or, if the vehicle is a 2005 or newer model, you can enter the VIN and the
GDS will determine that information for you. Once the vehicle has been identified, select "ECU
Upgrade" located under the "Vehicle SW Management" tab. (See Figure 1.) Note: The Vehicle
Communication Interface (VCI) connects to the vehicle via the Data Link Connector (DLC); and the
VCI must be connected to the GDS PC using the USB connection. (Some other GDS functions
allow for wireless communication between the VCI and GDS PC.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 408
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The FCU Upgrade screen will appear. Select "Auto Mode." (See Figure 2.) The GDS will prompt
you to make sure that you have connected the VCI to the DLC and turned on the VCI power. (See
Figure 3.) After making sure, click "OK."
A window will appear to alert you that the GDS is "ROM ID Reading." During this time, the GDS will
check for available reprograms for the vehicle's FCU. If any reprograms are found, the ROM ID will
be listed in the "Current ROM ID" window. The "Current ROM ID" window shows the existing status
of programming in the FCU. Note: If the ROM IDs match, the ECU already has the latest
reprogramming or your GDS unit needs to have the latest updates installed. Refer to the chart on
page 5. The TCM ID column lists the latest ID for each condition. Go to the right edge of the
"Upgrade Event" window and click on the down arrow. Available upgrade events will be displayed
in a drop down box. When you select one, the "Upgrade" button will appear in the center of your
screen. (See Figure 4.)
After you have selected the event, click "Upgrade," you will be asked to confirm that you want to
upgrade. Then, you will be prompted to wait while everything is verified. If there is a corresponding
TSB for the upgrade, another pop-up will give you the option to recall it and familiarize yourself with
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 409
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Once programming begins, the screen will display a status bar which monitors the reprogramming
process. (See Figure 5)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 410
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When the reprogramming has finished and the status bar reads "100%," another pop-up will direct
you to turn the ignition off for 10 seconds and turn it back on. When you click "OK" a second
pop-up will prompt you to reset the automatic transaxle adaptive learning values. Note: Do not do
any other activity with your GDS until the reprogramming is completed. (See Figure 6.) To reset the
Automatic Transaxle Adaptive Learning Values, click the "System" button toward the top of the
screen. The "GDS System Search" screen will appear and from it select "A/T." Then, choose the
"Resetting A/T Values" option. When the "Resetting A/T Values" screen (See Figure 7) appears,
click on "reset." A confirming pop-up will ask, "Are you sure?" Click "OK" and the values will be
reset and reprogramming will be complete.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > tnt1630506-01 > May > 06 > A/T Controls - PCM/TCM
Reset/Relearn Adaptive Values
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Engine Control Module: All Technical Service Bulletins A/T Controls - PCM/TCM Reset/Relearn
Adaptive Values
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. Here are the procedures
necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. Afier the following
repairs have been completed, the PCM/TCM adaptive values must be reset in order to provide
optimum shift quality:
HI-SCAN PROCEDURE:
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > tnt1630506-01 > May > 06 > A/T Controls - PCM/TCM
Reset/Relearn Adaptive Values > Page 416
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NOTE:
Adaptive learning does not occur below the ATF temperature range shown in next column:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 06-40-005 > Mar > 06 > A/T Controls - Reset and Relearn
Adaptive Values
2.
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Engine Control Module: All Technical Service Bulletins A/T Controls - Reset and Relearn Adaptive
Values
Group: TRANSAXLE
Number: 06-40-005
Model: ALL
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
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2005 MT-v
2005 MY-
BIG! IE EPIIII
THREE! I DELI RPI'I
HIGI I'IE BTH'I'E' I DIE
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 06-40-005 > Mar > 06 > A/T Controls - Reset and Relearn
Adaptive Values > Page 422
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR" "ACCEL. POS. S". or "ACCEL PEDAL 1
VOLT", depending on model).
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi- Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the accelerator pedal steady at a throttle position
sensor value of 1.45-1.75v during several 1-2-3-4 upshifts. Repeat until normal gear transitions
occur.
NOTE:
Adaptive learning does not occur below the ATF temperature range previously shown.
WARRANTY INFORMATION:
: ; »
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Engine Control Module: All Technical Service Bulletins A/T - TCM/ECM Adaptive Value
Rest/Relearn Procedure
Group:AUTOMATIC TRANSAXLE
Number: 11-AT-008
Model: ALL
This bulletin supersedes TSB 10-AT-Oil to include 2011~ Elantra, 2012~ Accent and Genesis
Sedan.
After replacing a transaxle or reprogramming the PCM/TCM, follow this procedure to reset and
relearn the adaptive learning to improve shift quality.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
arm: jam- m
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NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
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6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified TPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Engine Control Module: > 11-AT-008 > Apr > 11 > A/T - TCM/ECM Adaptive Value Rest/Relearn
Procedure > Page 431
Adaptive learning occurs only within the ATF temperature ranges shown.
WARRANTY INFORMATION:
“Mum m m F m
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Sula-ct Sygtnm SEI acted System
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Engine Control Module: All Technical Service Bulletins A/T Controls - Resetting PCM/TCM
Adaptive Values
Number: 10-AT-Oil
Model: ALL
Subject
This bulletin supersedes TSB 09-AT-002-1 to include Equus and Sonata HEV
CAUTION:
After replacing a transaxle or reprogramming the PCM/TCM, to improve the shift quality condition,
follow this procedure to reset and relearn the adaptive learning.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
HDTE: * Clear BAH Laarnahla sum: only If Mmhatrunlu {valva may: I: filfihfll’lflifl mam Inufllfl mun
[El-fillil 1.6L. Equus LEI. and GHI-flil- Gnupl 3.5L with 2F trim-ninth}.
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
m m m w w m fl n
' 1 ? t 'l-5 I."
6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified IPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Engine Control Module: > 10-AT-011 > Aug > 10 > A/T Controls - Resetting PCM/TCM Adaptive
Values > Page 439
NOTE:
Adaptive learning occurs only within the ATF temperature ranges shown:
WARRANTY INFORMATION:
Normal warranty applies
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Engine Control Module: > tnt1660906-03 > Sep > 06 > A/T, Engine Controls - ECM/TCM
Reset/Relearn Procedure
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EHTUURI'IEE BBL HM. EIIIE M‘l'r-
Engine Control Module: All Technical Service Bulletins A/T, Engine Controls - ECM/TCM
Reset/Relearn Procedure
MODEL: All
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This article provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. After the
following repairs have been completed, the PCM/TCM adaptive values must be reset in order to
provide optimum shift quality:
Adaptive values must be reset using procedure # 1 or # 2 according to model and model year (MY)
as shown below.
VEHICLES AFFECTED:
^ All
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P."
^ Select vehicle
press "ENTER"
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
NOTE:
Adaptive learning does not occur below the ATF temperature range shown.
WARRANTY INFORMATION:
4 —
.1: G D E‘Igfiéwr - Lllrl' “an I DI-EEII'ID'HIE til-II“: j“.- l'u'.:-1EI:I.'_-:'.' I HDPEIEII' a m DFF I fill-IL:-
-:r-. . I- - '. EHHTEH1'a 33w Dal-n: :-:.':.I..-m ENENEIB 3.91m DUI-I: .‘a-
7
vwxawuamfig: fl Efluwumm
ECU Upgrade
i huntflfllln
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final-ml Hana
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Engine Control Module: All Technical Service Bulletins Engine Controls - ECU Reprogramming
Procedure
Reprogramming
This issue of TechNet Times focuses on reprogramming. In the current Hyundai service
environment, reprogramming can be accomplished with the Hi-Scan Pro or Hyundai's new Global
Diagnostic System (GDS). We begin here with an overview of the process of reprogramming the
ECU as performed using the GDS on a 2006 Azera that experiences a 1-2 shift hesitation under
wide open throttle operation when cold. As with most GDS features, you must select the model,
year and system in order to get started. You can manually enter the information by selecting
drop-down box options or, if the vehicle is a 2005 or newer model, you can enter the VIN and the
GDS will determine that information for you. Once the vehicle has been identified, select "ECU
Upgrade" located under the "Vehicle SW Management" tab. (See Figure 1.) Note: The Vehicle
Communication Interface (VCI) connects to the vehicle via the Data Link Connector (DLC); and the
VCI must be connected to the GDS PC using the USB connection. (Some other GDS functions
allow for wireless communication between the VCI and GDS PC.)
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Procedure > Page 450
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The FCU Upgrade screen will appear. Select "Auto Mode." (See Figure 2.) The GDS will prompt
you to make sure that you have connected the VCI to the DLC and turned on the VCI power. (See
Figure 3.) After making sure, click "OK."
A window will appear to alert you that the GDS is "ROM ID Reading." During this time, the GDS will
check for available reprograms for the vehicle's FCU. If any reprograms are found, the ROM ID will
be listed in the "Current ROM ID" window. The "Current ROM ID" window shows the existing status
of programming in the FCU. Note: If the ROM IDs match, the ECU already has the latest
reprogramming or your GDS unit needs to have the latest updates installed. Refer to the chart on
page 5. The TCM ID column lists the latest ID for each condition. Go to the right edge of the
"Upgrade Event" window and click on the down arrow. Available upgrade events will be displayed
in a drop down box. When you select one, the "Upgrade" button will appear in the center of your
screen. (See Figure 4.)
After you have selected the event, click "Upgrade," you will be asked to confirm that you want to
upgrade. Then, you will be prompted to wait while everything is verified. If there is a corresponding
TSB for the upgrade, another pop-up will give you the option to recall it and familiarize yourself with
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Procedure > Page 451
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Once programming begins, the screen will display a status bar which monitors the reprogramming
process. (See Figure 5)
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Procedure > Page 452
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When the reprogramming has finished and the status bar reads "100%," another pop-up will direct
you to turn the ignition off for 10 seconds and turn it back on. When you click "OK" a second
pop-up will prompt you to reset the automatic transaxle adaptive learning values. Note: Do not do
any other activity with your GDS until the reprogramming is completed. (See Figure 6.) To reset the
Automatic Transaxle Adaptive Learning Values, click the "System" button toward the top of the
screen. The "GDS System Search" screen will appear and from it select "A/T." Then, choose the
"Resetting A/T Values" option. When the "Resetting A/T Values" screen (See Figure 7) appears,
click on "reset." A confirming pop-up will ask, "Are you sure?" Click "OK" and the values will be
reset and reprogramming will be complete.
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Other Service Bulletins for Engine Control Module: > tnt1630506-01 > May > 06 > A/T Controls - PCM/TCM Reset/Relearn
Adaptive Values
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Engine Control Module: All Technical Service Bulletins A/T Controls - PCM/TCM Reset/Relearn
Adaptive Values
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. Here are the procedures
necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. Afier the following
repairs have been completed, the PCM/TCM adaptive values must be reset in order to provide
optimum shift quality:
HI-SCAN PROCEDURE:
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
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Adaptive Values > Page 458
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NOTE:
Adaptive learning does not occur below the ATF temperature range shown in next column:
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Values
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Engine Control Module: All Technical Service Bulletins A/T Controls - Reset and Relearn Adaptive
Values
Group: TRANSAXLE
Number: 06-40-005
Model: ALL
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
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1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
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Values > Page 464
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR" "ACCEL. POS. S". or "ACCEL PEDAL 1
VOLT", depending on model).
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi- Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the accelerator pedal steady at a throttle position
sensor value of 1.45-1.75v during several 1-2-3-4 upshifts. Repeat until normal gear transitions
occur.
NOTE:
Adaptive learning does not occur below the ATF temperature range previously shown.
WARRANTY INFORMATION:
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466
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467
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- Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
3
Symbols Part 1
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and Instructions > Page 475
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- Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 476
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 482
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 483
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 484
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 485
DDHNEGTDH [1'3144-1]
§
I
H
$
t"!
3 .1.
D
2
2
Dmrlntion fiuflnlflltl tu
M
W W Cantu!
Fur Autatrunsaula Gmh'ul
Fur W e : Bantu!
Fur Autuh'msalda Gmtml
Fur Autuhmatuda Cmu'ul
Glutuh Switm uiunal input Gruiau Glufl'l Pad! Fuuflhn Snitch
Fur m m : Gmuul
Fur Hummus curmul
— l — _ — F — ' — F —
i7
n
Air candltlener Pl'lllul'l- Banner signal input
i
n
n
5'5"" ""3"“
AI" Cmdltmer Praaatl'a Samar. Fewer Steerhg
Praaaura SHEET {PEPE}
Dismiplion
.. ‘
55 Honour Fowsr Supply (+514!) A" Emmagiflflflglfiflw Fowsr Elfifi'll'lii
n For m u m : Contml
n Throtlis Fsslflon Bansor lions! iPWM} nullaut ABS Cultist luloduls. ESP Control Illloduls
Bruise 'MAIN' Ilmp oonl'ui output Gluiss 'MAIN' La'rlp
u Fusl Pump Finlay oonuoi outpll Fusi Plunp Relay
- 71 Variable Intake Sobnoid Volvo oontroi milput Unishto inislss Soisnnid WIS] 1|Ill'slus
Immohillzsr lsmp oonlrol output ln'lrlohlllzsr Lamp
For m m Gondoi
_TH Puma Bouillol Buimuid “also mnh'oi output Furgo Gontroi tnoid m {FGB‘U‘}
'4
to
Whool Speed Ssnsor [Low] signal input inmost Eposd Emsor Mfijrmihout ABSJ'ESF']
t s l Eposd Sensor [High] signal input t s l Speed Esnsor UHSSIMflhout ABSIESF]
E
CI
:1
E
:a
G
2
E
—I.
é
”I
2
Samuel-d ta
EI'S lulatar H aantral aulptn EI'G Matar [In ETl'; Maaula}
n Mmlhld Ahaaltla Fraaaurae Sanaar signal Imut Mmllalrl Abaaluta Fraaaura Samar {MAPS}
n Far Autatranaaada Sana-at
_ Samfl'rafl Faailian Samar {Bark 2] graunrl Camshaft Faalian Samar {SHIPS} [Elmlr 2]
n Samahal‘lllan SanaarlSanl: 1] annual! Camshaft Faallan SanaarlSHPSHSanH]
n Imitian Sat [Cylindar #Sl aantral aulaul Innllian Sal {WIinrlar #S}
u
u Sranlratflt Paalllan Sanaar [l-Igh] alnnal Input alumna F'aalflan Sanau' [SHIPS]
Far W Em m
m
E - HaatadflxymnSl'raarEBmkEISamarflgaund HaataarganSanaarfl-IDESJMmHElSanaaH
l — fl
u l-IaalaaayganSa'laarmmlrElSanaarflywnd HaaladyganSanaartHDESlmmlrzlSanaarE
n mama mammal: 1 15m “ma Haatad oxygan Sanaarll-IDESHSEIIIH lSanaar‘l
n Haatarl Own Sanaar [Bank 1 .-' Sanaar 2] graund Haalarl Oxygen Sanaar [HESS] [Bank 1 l' Sanaar 2]
Gamahaft Fnaiflm Sanaar [Emit 1] mar aupphr Gamahfl't Palltlan Samar [SHIPS] [Bank 1]
Enma Saatmt Tarnparatura Sanaar nraunll Ennlna ll."laalant Tarnpalatlra Sanaar [ESTS]
Manlhld-Abaaluta Fraaaura Sanaar {MP5}.
CWT S11 Tan'param Sanaar {DIS}
Bhaaala Graund
_
Chaaala Grauna
_ _ _ . — .
PCM Terminal Function - Connector (C144-2) Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions > Page 489
— r — I - — — u' —
Deteripflan Canneated ta
Chassis Grauna
Patter gauntl Ct1easleCratl1d
Fewer yet-1a Illitt Emma
Ianillan Call [Cyllntllr #41aantral autput lgn‘tlim Cail [Cylinder #4}
Crankfl'tdt Paeilien Sertttt'n' new] signal haul Crankshaft Pattillan Senear {CHIPS}
42 Far Autah'artaaxla Central
n
n
Far manna-axle Central
Far mmaanwae Canaan
n
u
Far mtalranaeatle Central
m e w sat-mar [Bank 2 F EH15" l-Ieetea Oxygen Senaar {HC25} [nut 21' Senlar 2}
u
n
Hnaalt Senear {HS}#2 [l-llgn] signal Input
HI‘lDC-I'L Belem [HS]: #2 [Law] Signal injlul.
HHCCII. ESHSCI" [H5] #2 [Huh]
Hllufllt EIII'IIEI'LI (H3) #2 [Lulu]
n
u
Sneak Samar {KS}#1 [La-HI signal input
lineal-t Senear {HS} #1 [High] elgrtel Input
Knaalt Sensor {K8} #1 [Lair]
Knack Seneer [KS] #1 [nh]
n 53
Thratlle Paeltlan Sertaer #2 algnfl input
Thrntlle Paeit‘nn Set-tater #2 nutmd
Thratlle Paetlian Senaar {FPS} #2
11'trettle Punillm Serteer {11:5} #2
59 Far nutattaneaztle Central
lgnltlan Cail {Cfi'tdar #2} ant-that auttaut Inritiart Call {Cyli'ttler #2]
CWT Cil Canaal Viva [Benlt 2] aanlral autput CWT Cll Cantral Valve {CCU} [Bantu 2]
CWT Ci t a fl fl l t _1]_aarttr_1_.'tl_eutpll_t CWT CII Emtral Valve {CCU} [Berlt 1]
inhaler {entree #2] aanlral «:11t 5' Mtcfiwfit “ _ —' ’—
.mmmmanna mm
fulfil: WEE“ EBI'IIDT [BEBE 2 .l' SEMI"
1] HSHIHI' aanlml output Hm Dxraan 5mlHflEE-l [Bank 2 t E'tenltnr 1]
ummmmm: mm: mm
as mammal-marmmw
_ T1
l-lettled Oxygen Smear [Emit 1 lSansar
uducripflnn ‘ -. £ 1 : a tr.-
lnjm {Gylhder #1} mntml uulput njautm' { t u ' #1}
5'1““ mam “ [Bank 2 I Samar Hunted Oxygen “(Heisman-1:2 {Sunni}
mmnsmww w
Hilary
Imfllnn Call [may #3) annual nuiput Innlflun col {Cyllndar #3}
mififln Gail [Gym #5} animal nutput Ignlflm Cal {Cyllntlar #5}
__ ggnrHun Call [cum #1} cmtml mam“ Ignfllun Gui {Cylinder #1}
EDHHEETDR [mu-1]
' Fin
q
i
Ha.
E‘
II 2nd CM [High]
H 2!“ CAN [LN]
H Fur Autuflansaxla Cmtnl
II FIJI Autulmnsaxla Gml
E
Hinh: Bum
2
m m load aimai input PULSE Lulu: Max. 1.
140 -- mm:
m W“ W ““1"" - _ -
E m m W m mm “ m
iilliili
-
null.
fl
Fur mmuamxla Gmimi
i
Emil: pedal
21 Baum slgnal Input
E
3
i3
I Fm Marla-urn Cantu!
Laval insult
E
5
2? Diagnaafla Dal: Lila {Ii-Lina} HlflT lulh
m u m
E
m
E
Ba'llarjqI vallaua supply altar mail ralay
'2 E E
Battarr unltaua amplyafiarmaln ralagllr
3
cm
E
aE2
E
E
El
w
4? Hana Air Fll'fll' Samar alpnil lrput — -
3.0mm
— —
”WWW “ m
1%
Pasilian Samar _|
. :13 ~ aw
n
Aaaalaralar
#2 m w
Far Pulatansafla t ' a l
w “”9 m -
Waa 'SET' lamp aanll'al autput
.5
E
'2
52 1lnI'IIlIl-Iiala speed almal hput 1Inl'hlhiala running
#1 algnal Input
-l
5’
Aaaalaralar Pauilian Emaar
'U'l
W
#1 gaund
3;
IHEH'
a
ar Vraf
Law: Max. 0.5?
53
Malfunalian lndlaaliar Lamp {MIL} Hlm: Battery Wilma 4
aantral aulput MIL a."
g
.2'
3
if."
i
Dun-inflon Gundltim
Hill
I
g
-57'
~= E
g5
5i
H
m
Tfluttla Fultlun Samar almal
{PWMIWIPIII
I
FF
TI}
E:E
a
E
I 1" I W "I”. Emu m
annual mm Iranllva
T
-4 1-1 -.I -.1
E5
ia
:Imal input
Wheat Speed Samar [Hluh]
El
D
Elana [13:51!
CDMHECTDR [0144-2]
:2: mm
i
E
E
E
ETC: Habit H m Dub"!
Pin
Ha.
2 2 —
Ella-NEH“
%“mu
flE—Ennnnmmmgm
4Garqshaflfulflhn Bum [Bank
.
c m Podium 5 m [Bank
1] signs! Input
.
r m 1] yuund
I'llltfld Oxygen 53m [Bank 2
J'Eansnr 2] [ 1 e
:
Haaladflxmnfiammmm
Faerunrflg'wnd
I-laaladygaalurlflmH
Imamnd
Man; H.511?
Crflfllfill'll'fl Ila-Him E m
.
mi. —
.
PCM Terminal Input/Output Signal - Connector (C144-2) Part 2
"
3
l
P
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
.
and Instructions > Page 497
m
a
I
g
Daaarlptlan
I
Thralfla Paalflan Samar #1
ll tipnal Input
Ill-ml- Wa
.
WWI-1SanaarlH Ermine Hmninn
.
I
n
—
.
finaakBanaarmgjpzfl-liw
i.
El
walnut {KB} #2 [Lou]
I-lfl-I
|
Ilpnal Irumt
limd Input I m
H
U
'55 ThratflaFaIiflmsanaarfln‘aund
59 FarAutat'anaafllacanlral
WWW
. LEV 11w
am a: aunt-a1 nah-a {Bank
2] aaniral autput
“In nil-amine the 13H:
Tm
m
n
m
m
m
Ha.
High: B M W “ 13.3“
m
Vpaak: m. HEN
a. m
Heated Men Eenaal' [Bank 2 J"
TI
High: Batterytfaflane
Lilli: Matt. LEV
.
Ini-eeter [wilder #1} animal autput
Vpeak: ”Hal. BEN
mm
mm
W
W
m
m
m
.
.
wmwMmm
a:
T5 _
W _
_ - m: — — -
m _ — m — m
an: flux. 2*:
m
mflfi'mn}
mm numut
1. TEST PCM GROUND CIRCUIT: Measure resistance between PCM and chassis ground using
the backside of PCM harness connector as PCM
2. TEST PCM CONNECTOR: Disconnect the PCM connector and visually check the ground
terminals on PCM side and harness side for bent pins
3. If problem is not found in Step 1 and 2, the PCM could be faulty. If so, replace the PCM with a
new one, and then check the vehicle again. If the
vehicle operates normally then the problem was likely with the PCM.
4. RE-TEST THE ORIGINAL PCM : Install the original PCM (may be broken) into a known-good
vehicle and check the vehicle. If the problem
occurs again, replace the original PCM with a new one. If problem does not occur, this is
intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION
PROCEDURE). See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Component Tests and General Diagnostics/Electronic Component Inspection
Procedures
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection >
Component Tests and General Diagnostics > Page 502
DDHNEGTDH [1'3144-1]
§
I
H
$
t"!
3 .1.
D
2
2
Dmrlntion fiuflnlflltl tu
M
W W Cantu!
Fur Autatrunsaula Gmh'ul
Fur W e : Bantu!
Fur Autuh'msalda Gmtml
Fur Autuhmatuda Cmu'ul
Glutuh Switm uiunal input Gruiau Glufl'l Pad! Fuuflhn Snitch
Fur m m : Gmuul
Fur Hummus curmul
— l — _ — F — ' — F —
i7
n
Air candltlener Pl'lllul'l- Banner signal input
i
n
n
5'5"" ""3"“
AI" Cmdltmer Praaatl'a Samar. Fewer Steerhg
Praaaura SHEET {PEPE}
Dismiplion
.. ‘
55 Honour Fowsr Supply (+514!) A" Emmagiflflflglfiflw Fowsr Elfifi'll'lii
n For m u m : Contml
n Throtlis Fsslflon Bansor lions! iPWM} nullaut ABS Cultist luloduls. ESP Control Illloduls
Bruise 'MAIN' Ilmp oonl'ui output Gluiss 'MAIN' La'rlp
u Fusl Pump Finlay oonuoi outpll Fusi Plunp Relay
- 71 Variable Intake Sobnoid Volvo oontroi milput Unishto inislss Soisnnid WIS] 1|Ill'slus
Immohillzsr lsmp oonlrol output ln'lrlohlllzsr Lamp
For m m Gondoi
_TH Puma Bouillol Buimuid “also mnh'oi output Furgo Gontroi tnoid m {FGB‘U‘}
'4
to
Whool Speed Ssnsor [Low] signal input inmost Eposd Emsor Mfijrmihout ABSJ'ESF']
t s l Eposd Sensor [High] signal input t s l Speed Esnsor UHSSIMflhout ABSIESF]
E
CI
:1
E
:a
G
2
E
—I.
é
”I
2
Samuel-d ta
EI'S lulatar H aantral aulptn EI'G Matar [In ETl'; Maaula}
n Mmlhld Ahaaltla Fraaaurae Sanaar signal Imut Mmllalrl Abaaluta Fraaaura Samar {MAPS}
n Far Autatranaaada Sana-at
_ Samfl'rafl Faailian Samar {Bark 2] graunrl Camshaft Faalian Samar {SHIPS} [Elmlr 2]
n Samahal‘lllan SanaarlSanl: 1] annual! Camshaft Faallan SanaarlSHPSHSanH]
n Imitian Sat [Cylindar #Sl aantral aulaul Innllian Sal {WIinrlar #S}
u
u Sranlratflt Paalllan Sanaar [l-Igh] alnnal Input alumna F'aalflan Sanau' [SHIPS]
Far W Em m
m
E - HaatadflxymnSl'raarEBmkEISamarflgaund HaataarganSanaarfl-IDESJMmHElSanaaH
l — fl
u l-IaalaaayganSa'laarmmlrElSanaarflywnd HaaladyganSanaartHDESlmmlrzlSanaarE
n mama mammal: 1 15m “ma Haatad oxygan Sanaarll-IDESHSEIIIH lSanaar‘l
n Haatarl Own Sanaar [Bank 1 .-' Sanaar 2] graund Haalarl Oxygen Sanaar [HESS] [Bank 1 l' Sanaar 2]
Gamahaft Fnaiflm Sanaar [Emit 1] mar aupphr Gamahfl't Palltlan Samar [SHIPS] [Bank 1]
Enma Saatmt Tarnparatura Sanaar nraunll Ennlna ll."laalant Tarnpalatlra Sanaar [ESTS]
Manlhld-Abaaluta Fraaaura Sanaar {MP5}.
CWT S11 Tan'param Sanaar {DIS}
Bhaaala Graund
_
Chaaala Grauna
_ _ _ . — .
PCM Terminal Function - Connector (C144-2) Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection >
Component Tests and General Diagnostics > Page 506
— r — I - — — u' —
Deteripflan Canneated ta
Chassis Grauna
Patter gauntl Ct1easleCratl1d
Fewer yet-1a Illitt Emma
Ianillan Call [Cyllntllr #41aantral autput lgn‘tlim Cail [Cylinder #4}
Crankfl'tdt Paeilien Sertttt'n' new] signal haul Crankshaft Pattillan Senear {CHIPS}
42 Far Autah'artaaxla Central
n
n
Far manna-axle Central
Far mmaanwae Canaan
n
u
Far mtalranaeatle Central
m e w sat-mar [Bank 2 F EH15" l-Ieetea Oxygen Senaar {HC25} [nut 21' Senlar 2}
u
n
Hnaalt Senear {HS}#2 [l-llgn] signal Input
HI‘lDC-I'L Belem [HS]: #2 [Law] Signal injlul.
HHCCII. ESHSCI" [H5] #2 [Huh]
Hllufllt EIII'IIEI'LI (H3) #2 [Lulu]
n
u
Sneak Samar {KS}#1 [La-HI signal input
lineal-t Senear {HS} #1 [High] elgrtel Input
Knaalt Sensor {K8} #1 [Lair]
Knack Seneer [KS] #1 [nh]
n 53
Thratlle Paeltlan Sertaer #2 algnfl input
Thrntlle Paeit‘nn Set-tater #2 nutmd
Thratlle Paetlian Senaar {FPS} #2
11'trettle Punillm Serteer {11:5} #2
59 Far nutattaneaztle Central
lgnltlan Cail {Cfi'tdar #2} ant-that auttaut Inritiart Call {Cyli'ttler #2]
CWT Cil Canaal Viva [Benlt 2] aanlral autput CWT Cll Cantral Valve {CCU} [Bantu 2]
CWT Ci t a fl fl l t _1]_aarttr_1_.'tl_eutpll_t CWT CII Emtral Valve {CCU} [Berlt 1]
inhaler {entree #2] aanlral «:11t 5' Mtcfiwfit “ _ —' ’—
.mmmmanna mm
fulfil: WEE“ EBI'IIDT [BEBE 2 .l' SEMI"
1] HSHIHI' aanlml output Hm Dxraan 5mlHflEE-l [Bank 2 t E'tenltnr 1]
ummmmm: mm: mm
as mammal-marmmw
_ T1
l-lettled Oxygen Smear [Emit 1 lSansar
uducripflnn ‘ -. £ 1 : a tr.-
lnjm {Gylhder #1} mntml uulput njautm' { t u ' #1}
5'1““ mam “ [Bank 2 I Samar Hunted Oxygen “(Heisman-1:2 {Sunni}
mmnsmww w
Hilary
Imfllnn Call [may #3) annual nuiput Innlflun col {Cyllndar #3}
mififln Gail [Gym #5} animal nutput Ignlflm Cal {Cyllntlar #5}
__ ggnrHun Call [cum #1} cmtml mam“ Ignfllun Gui {Cylinder #1}
EDHHEETDR [mu-1]
' Fin
q
i
Ha.
E‘
II 2nd CM [High]
H 2!“ CAN [LN]
H Fur Autuflansaxla Cmtnl
II FIJI Autulmnsaxla Gml
E
Hinh: Bum
2
m m load aimai input PULSE Lulu: Max. 1.
140 -- mm:
m W“ W ““1"" - _ -
E m m W m mm “ m
iilliili
-
null.
fl
Fur mmuamxla Gmimi
i
Emil: pedal
21 Baum slgnal Input
E
3
i3
I Fm Marla-urn Cantu!
Laval insult
E
5
2? Diagnaafla Dal: Lila {Ii-Lina} HlflT lulh
m u m
E
m
E
Ba'llarjqI vallaua supply altar mail ralay
'2 E E
Battarr unltaua amplyafiarmaln ralagllr
3
cm
E
aE2
E
E
El
w
4? Hana Air Fll'fll' Samar alpnil lrput — -
3.0mm
— —
”WWW “ m
1%
Pasilian Samar _|
. :13 ~ aw
n
Aaaalaralar
#2 m w
Far Pulatansafla t ' a l
w “”9 m -
Waa 'SET' lamp aanll'al autput
.5
E
'2
52 1lnI'IIlIl-Iiala speed almal hput 1Inl'hlhiala running
#1 algnal Input
-l
5’
Aaaalaralar Pauilian Emaar
'U'l
W
#1 gaund
3;
IHEH'
a
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection >
.
Component Tests and General Diagnostics > Page 514
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Engine Control Module: Service and Repair
VIN (Vehicle Identification Number) is a number that has the vehicle's information (Maker, Vehicle
Type, Vehicle Line/Series, Body Type, Engine Type, Transmission Type, Model Year, Plant
Location and so forth). When replacing an PCM, the VIN must be programmed in the PCM. If there
is no VIN in PCM memory, the fault code (DTC P0630) is set.
CAUTION: The programmed VIN cannot be changed. When writing the VIN, confirm the VIN
carefully.
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WARNING: Before pressing the "ENTER" key, confirm the VIN again because the programmed
VIN cannot be changed.
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6. Turn the ignition switch OFF; and then turn ON. 7. Verify the programmed VIN in the PCM
memory.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 523
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 528
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 531
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 534
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 535
35
3
Symbols Part 1
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 536
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 537
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Instructions > Page 539
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Instructions > Page 540
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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Instructions > Page 541
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 542
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 543
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Instructions > Page 544
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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- Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 545
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules
- Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 549
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Diagram Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 556
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Component Information > Diagrams > Diagram Information and Instructions > Page 559
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Component Information > Diagrams > Diagram Information and Instructions > Page 560
l
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Symbols Part 1
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Component Information > Diagrams > Diagram Information and Instructions > Page 561
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 562
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Component Information > Diagrams > Diagram Information and Instructions > Page 568
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 571
The primary purpose of the SRSCM (Supplemental Restraints System Control Module) is to
discriminate between an event that warrants restraint system deployment and an event that does
not. The SRSCM must decide whether to deploy the restrain system or not. After determining that
pretensioners and/or airbag deployment is required, the SRSCM must supply sufficient power to
the pretensioners and airbag igniters to initiate deployment.
The SRSCM determines that an impact may require deployment of the pretensioners and airbags
from data obtained from impact sensors and other components in conjunction with a safing
function. The SRSCM will not be ready to detect a crash or to activate the restraint system devices
until the signals in the SRSCM circuitry stabilize. It is possible that the SRSCM could activate the
safety restraint devices in approximately 2 seconds but is guaranteed to fully function after
prove-out is completed. The SRSCM must perform a diagnostic routine and light a system
readiness indicator at key-on. The system must perform a continuous diagnostic routine and
provide fault communication through a warning lamp indicator in the event of fault detection. A
serial diagnostic communication interface will be used to facilitate servicing of the restraint control
system.
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Component Information > Diagrams > Page 572
REMOVAL
1. Disconnect the negative(-) cable from battery and wait for at least 3 minutes. 2. Remove ignition
key from the vehicle. 3. Remove the center console.
4. Pull back the lever, then disconnect the SRSCM harness connector(A). Loosen the bolt(B), then
remove the SRSCM(C).
NOTE: -
Turn the ignition switch ON; the SRS indicator light should turn on for about six seconds and then
go off
SUMMARY: Hyundai is recalling 393,714 M/Y 2006-2008 Sonata vehicles equipped with an
advanced air bag system which features an Occupant Classification System (OCS) in the right front
seat. The purpose of the OCS is to disable the right passenger seat front air bag when it detects
the presence of a child restraint system or small child in the right front seat. The right front air bag
is disabled to prevent injuries to a child that may result from a right front air bag inflation during a
crash.
CONSEQUENCE: Misclassification of a small stature adult as a child in the right front passenger
seat may cause the right front air bag to not inflate in an accident that merits air bag deployment
and may result in injury to the right front occupant.
REMEDY: Dealers will verify that the OCS does not properly recognize a properly seated adult
occupant. After verification, dealers will remove the right front seat cushion assembly and ship it to
an evaluation and repair facility. This facility will evaluate and repair or reprogram the seat cushion
and OCS as necessary. The recall is expected to begin on or about May 26, 2008. Owners may
contact Hyundai at 1-800-633-5151.
NOTES: Hyundai recall No. 083. Customers may contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to
http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant
Classification Module - Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Seat Occupant Classification Module - Air Bag: > NHTASA08V161000 > Apr > 08 > Recall 08V161000: Air Bag System
Defect
Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Recall 08V161000:
Air Bag System Defect
MAKE/MODELS: MODEL/BUILD YEARS: Hyundai/Sonata 2006-2008 MANUFACTURER :
Hyundai-KIA America Technical Center Inc.
SUMMARY: Hyundai is recalling 393,714 M/Y 2006-2008 Sonata vehicles equipped with an
advanced air bag system which features an Occupant Classification System (OCS) in the right front
seat. The purpose of the OCS is to disable the right passenger seat front air bag when it detects
the presence of a child restraint system or small child in the right front seat. The right front air bag
is disabled to prevent injuries to a child that may result from a right front air bag inflation during a
crash.
CONSEQUENCE: Misclassification of a small stature adult as a child in the right front passenger
seat may cause the right front air bag to not inflate in an accident that merits air bag deployment
and may result in injury to the right front occupant.
REMEDY: Dealers will verify that the OCS does not properly recognize a properly seated adult
occupant. After verification, dealers will remove the right front seat cushion assembly and ship it to
an evaluation and repair facility. This facility will evaluate and repair or reprogram the seat cushion
and OCS as necessary. The recall is expected to begin on or about May 26, 2008. Owners may
contact Hyundai at 1-800-633-5151.
NOTES: Hyundai recall No. 083. Customers may contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to
http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
E. FIJI pump M
2+ Han-i lump why {High} 1'. Whur rally
3. Stan rally E. Alr nurtliiminn relay
4-. EfiE—I curtrd relay 9. Frunt flag mlay
5. NT rainy 1D. Hum Inlay
Component Location
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 590
"Ha: : ‘ F
--I-"-'I-l‘|— i'—II'
'=|_'_u-:. —__-',u-_ -||-_|_.,
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STARTER RELAY
INSPECTION
4. Apply 12 V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30
and 87. 5. If there is no continuity, replace the starter relay. 6. Install the starter relay. 7. Install the
fuse box cover.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set
Hut-ELM HDIIEL
199%11105 [EF] Emma
Ems-10 {HF} Samta
milk-DE [5M1- Samar“:
ram-HI] {EM} 5m F:
Human!) {HG} xfimsm
2m1~flfi {ED} Elflnlrra
11103-413 (GK) 11mm:
2mg [Ilufl Tmsun
m {TE} Am
lam—us [Emmuumge
Control Module: Customer Interest A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set
Group TRANSAXLE
Number 09-AT-018
Subject ATA SOLENOID DIAGNOSTIC TROUBLE CODES P0740, P0741, P0742, P0743, P0746,
P0748, P0750, P0755, P0760, P0765, P0770
This TSB supersedes TSB# 05-40-006 to change the test procedure (Step 5) and add additional
models.
DESCRIPTION:
Incorrect operation of the transaxle solenoids may result in the following symptoms:
^ Diagnostic Trouble Codes P0740, P0741, P0742, P0743, P0746, P0748, P0750, P0755, P0760,
P0765 or P0770 set
NOTE:
Do NOT replace the transaxle for solenoid codes listed as open/short. Instead, follow the repair
procedure shown below.
APPLICABLE VEHICLES:
NOTE:
Refer to TSB 09-AT-011 for 2007~10 (HD) Elantra Sedan and (FD)
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09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 606
PARTS INFORMATION
REPAIR PROCEDURE:
1. Using a GDS, check for DTC in both the "Engine" and "Automatic Transaxle" menus. Record the
DTC and description.
^ Vehicle
^ "Actuation Test"
^ Press the "Start" button and listen for a solenoid sound and "Success" indication.
^ Fail: go to Step 3
^ Success: the wiring between the PCM/TCM currently has no open or short circuits. Go to Step 4.
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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 607
J .I -'-JI l . l ' . l l l III'l-IIII-I luli I n Mr-
in!!!El" IHII'
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In SpEEHDI‘l I Test .-_._.,
MODEL Harman PM
4530131955:
Refer to parts catalog
45305—330“
NOTE:
This test confirms the wiring harness currently does not have an open or short circuit. It does not
confirm the proper functioning of the solenoids under all conditions of heat and vibration or a
solenoid with an intermittent open/short condition.
3. If Step 2 shows an inoperative solenoid, visually check the wiring harness between the TCM and
transaxle for a damaged wire or a short circuit to ground. Disconnect the connectors to the
solenoids at the transaxle and the PCM/TCM and check for a bent pin or a pin not fully inserted into
the connector. If so, repair or replace the ECM control harness, P/N 914xx-xxxxx.
4. Check the harness inside the transaxle oil pan for a short circuit to ground. Replace the harness
if damage is found or if three or more solenoid DTC are found in Step 1. (Refer to TSB#04-40-015
for replacement instructions).
5. Refer to the DTC recorded in Step 1 and follow the repair procedure shown below:
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09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 608
DTD REPAIR PRDEEDURE
I F0740. F0740. F0740. F0700. F0700. F0700.
F0705. F0770. F0740 at Ram-ea the related Inlanaidl
I F0743 {ll' F0740. F0741 0r F0742 Illfl let}
I P0740 [I70 duhh auntral syntarn pru-hllm} manlyr Clint “Ennina” and I*‘l'nlnla.'«:la" rnanu far 070:
I P0741 [WC duhh stuck all] ulnmlqI I ll' OTC P0330 nr P0720: Fallmu pmdura Hall.
I P0742 [1'10 dutch stuck an] ::Iln|3,I I lfng 0T0 P0330 ur P0720: Raplaua tha haul-:0-
[If nu afllar anlanuid 0T0 all)
P0330 (Crankshaft pualllnn annular rnalhncllnn} I check hill!!! and unnnaabara tn CHIP aanlnr
and ECWTGM. If DH. replace CHIP IIIIIDI'.
F0720 {GHF mam - 000“ almalt}
I fill!!! lullnnid DTG.
P1520 - TGlll MIL maul: algnal
Damned:
P0700 - TCM MIL mutual: algnal
0'0
LEE
RED
VFE
BITE REPAIR
10. Refer to the DTC recorded in Step 1 and replace the related solenoid according to the diagram
shown. Tighten the bolts to 4-5 lb.ft (50-70 kg.cm). Go to step 11.
11. Apply Permatex Ultra Gray Sealer or Hyundai Ultra Gray Gasket Sealer, P/N 00231-13800 to
the valve body cover and reinstall the cover. Tighten the bolts to 6-7 lb.ft (80-100 kg.cm).
12. Reinstall the radiator hoses and add ethylene glycol coolant to the radiator and overflow bottle.
Adjust the level according to the appropriate shop manual, "EM" section.
13. Add approximately five quarts of Hyundai SPIII ATF and check the level with the engine idling
in Neutral. Refer to TSB 06-40-016 and adjust the ATF level when the ATF is at normal operating
temperature (70-80°C, 158-176°F).
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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 609
14. Clear the codes and test drive the vehicle for two driving cycles (two key-on to key-off driving
cycles, including 1-2-3-4 upshifts and 4-3-2-1 downshifts). If the DTC returns, perform the repairs
shown above.
WARRANTY INFORMATION
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
08-AT-003 > May > 08 > A/T - Harsh/Delayed Upshift/Downshift
Control Module: Customer Interest A/T - Harsh/Delayed Upshift/Downshift
Group: AUTOMATIC TRANSAXLE
Number: 08-AT-003
Model: 1999~ SONATA, 2001~06 ELANTRA, 2001~ SANTA FE & XG, 2003~ TIBURON, 2005~
TUCSON, 2006~ AZERA, 2007~ ENTOURAGE
This TSB supersedes TSB 07-40-010 to correct the labor time for OP Code 95440RP0 and
95440PQ0.
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed upshift or downshift,
follow the Diagnostic Procedure shown below.
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue with the diagnosis.
4. Attach the GDS and check for Diagnostic Trouble Codes in both the "Engine" and "Automatic
Transaxle" menu. If DTC's are found, repair according to the appropriate TSB or shop manual.
NOTE:
"Current Data"
^ "Shift position"
^ "Vehicle speed"
^ Select "PC Record" (on left of screen) and save the file.
"Items List" (top right of screen) and select: "Vehicle speed" and "Shift position".
PCM/TCM DIAGNOSIS:
Confirm the PCM or TCM commanded each gear: 1, 2, 3, 4 and 5 (if equipped): ^
If so, go to pages 3~6 and evaluate the upshift diagnosis for the related shift.
If not, exchange a PCM or TCM from a properly operating vehicle and test again to determine if the
PCM or TCM commanded each gear:
^ If the condition is not improved, go to page 3~6 and evaluate the upshift performance.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Underdrive Solenoid Duty"
and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 1-2 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The 2nd solenoid elapsed time is important; the shape of the graph is not.
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I.'.l‘.l 'l'IH':I'I I
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "Underdrive Solenoid Duty", "Overdrive
Solenoid Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the OD solenoid elapsed time at the top right of the screen. If the 2-3 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive values":
NOTE:
The OD solenoid elapsed time is important; the shape of the graph is not.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Overdrive Solenoid
Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 3-4 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
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Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "Reduction Solenoid Duty", Low-Reverse
Solenoid Duty and "Shift Position".
^
Select the "+" or "-" button to choose 0.7 sec./Div or less.
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the LR solenoid elapsed time at the top right of the screen. If the 4-5 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION:
NOTE:
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08-AT-003 > May > 08 > A/T - Harsh/Delayed Upshift/Downshift > Page 617
Warranty Claim requires input of DTC codes on all claims using Hi-Scan or GDS operations. If no
DTC code is identified by the Hi-scan or GDS, enter P0000 as a Scan Tool Test Code on the
Warranty Claim and attach printout from the Hi-scan or GDS to the Repair Order.
NOTE:
Printouts must be attached to all Repair Orders. Repair Orders without attached printouts are
subject to chargeback.
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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement
mm
ATF at nen'nel eperetfng temperature {158-212°F, FBI-1ETC}
‘ —
Group: TRANSAXLE
Number: 07-40-009-1
Models: 1999 - SONATA 2001-06 - ELANTRA 2001 - SANTA FE & XG 2003 - TIBURON 2005 -
TUCSON 2006 - AZERA 2007 - ENTOURAGE
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed shift into Drive or
Reverse, follow the Diagnostic Procedure shown below:
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
2. Perform the adaptive learning by shifting from Neutral to Reverse and Drive, stopping in each
gear for 5 seconds. Repeat 10 times.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue the diagnosis.
4. Check that idle speed is within specification. If not, inspect according to the appropriate shop
manual, "Fuel System Section".
5. Check the engine and transaxle mounting brackets and roll support brackets. If necessary,
replace the mounts.
6. Attach the GDS and check for Diagnostic Trouble Codes in both the "ENGINE" and
"AUTOMATIC TRANSAXLE" menus. If DTC are found, repair according to the appropriate TSB or
shop manual.
7. Attach the GDS and select "AUTOMATIC TRANSAXLE" menu, "CURRENT DATA" menu and
"FLUID TEMPERATURE SENSOR". Confirm the oil temperature sensor operates correctly as
shown. If not, inspect the oil temperature sensor according to TSB 04-40-016 or appropriate shop
manual.
8. Select "CURRENT DATA" and "TPS". Open and close the throttle and confirm the TPS
increases and decreases smoothly between approximately 0 - 100% duty.
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07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 622
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9. Attach the GDS and select VIN and "A/T" "Current Data" and then select "Shift Position", "LR
Solenoid Duty" and "Underdrive Solenoid Duty" as shown.
10. Start the engine and move the shift lever between Neutral, Drive and Reverse, stopping 3-5
seconds in each gear.
11. Select "Record shown" at the top right of the screen. GDS will record up to 10 minutes data
prior to selecting "Record".
12. Select "PC Record" (top left of screen), then save file.
13. Select "Flight Record" and "Data Review", select the vehicle and open the file.
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07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 623
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14. Select "Items List" (top right of screen), then select "Shift Position", "LR Solenoid Duty" and
"Underdrive Solenoid Duty".
16. Move the cursor to the start of the shift and "Left click".
17. Move the cursor to the end of the shift and "Right Click".
18. Read the Low & Reverse solenoid engagement time on the top right of the screen. If the P-R
shift requires more than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle
and follow TSB 06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
20. Select "Items List" (top right of screen), then select "Shift Position LR Solenoid Duty" and
"Underdrive Solenoid Duty".
22. Move the cursor to the start of the shift and "Left click".
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07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 624
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NDTE: Warranty Claim requlrea Input cf DTG ccclea an all claims ualng Hl-Scan
cr GEE cperatiene. H' nc DTL": cede ie identified by the Hi-ecan er GDS,
enter Fflflflfl aa a Scan cl Teat Code on the Warranty Claim and attach
plintcut frcrn the Hi-acan er GDS tn the Repair Grder.
NDTE: Frintcuta must be attached to all Repair Drdars. Repalr Orders wlthcut
attached printcuts are subject tc chargeback.
23. Move the cursor to the end of the shift and "Right Click".
24. Read the UD engagement time on the top right of the screen. If the P-D shift requires more
than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The UD solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION
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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest: >
05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE'
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DIG are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
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4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
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8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
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05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 631
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^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
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05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 632
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
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Control Module: All Technical Service Bulletins A/T - TCM/ECM Adaptive Value Rest/Relearn
Procedure
Group:AUTOMATIC TRANSAXLE
Number: 11-AT-008
Model: ALL
This bulletin supersedes TSB 10-AT-Oil to include 2011~ Elantra, 2012~ Accent and Genesis
Sedan.
After replacing a transaxle or reprogramming the PCM/TCM, follow this procedure to reset and
relearn the adaptive learning to improve shift quality.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
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[Gene-II ASL. Equal MEL, and Gene-II Camp-e 33L wlfl'u 2F Inn-mlnlun].
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
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6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified TPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
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Bulletins: > 11-AT-008 > Apr > 11 > A/T - TCM/ECM Adaptive Value Rest/Relearn Procedure > Page 641
NOTE:
Adaptive learning occurs only within the ATF temperature ranges shown.
WARRANTY INFORMATION:
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Control Module: All Technical Service Bulletins A/T Controls - Resetting PCM/TCM Adaptive
Values
Number: 10-AT-Oil
Model: ALL
Subject
This bulletin supersedes TSB 09-AT-002-1 to include Equus and Sonata HEV
CAUTION:
After replacing a transaxle or reprogramming the PCM/TCM, to improve the shift quality condition,
follow this procedure to reset and relearn the adaptive learning.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
HDTE: * Clair BAH Laarnahla sum: only If Manhatrunlu mm may: Is unchanged mam Inufllfl which
[El-fillil 1.6L. Equus LEI. and GHI-flil- Gnupl 3.5L with 2F trim-ninth}.
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
4. Attach a GDS and select VIN and A/T
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Bulletins: > 10-AT-011 > Aug > 10 > A/T Controls - Resetting PCM/TCM Adaptive Values > Page 648
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6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified IPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
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Bulletins: > 10-AT-011 > Aug > 10 > A/T Controls - Resetting PCM/TCM Adaptive Values > Page 649
NOTE:
Adaptive learning occurs only within the ATF temperature ranges shown:
WARRANTY INFORMATION:
Normal warranty applies
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Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set
Hut-ELM HDIIEL
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11103-413 (GK) 11mm:
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Control Module: All Technical Service Bulletins A/T - MIL ON/Failsafe Mode/Multiple Solenoid
DTC's Set
Group TRANSAXLE
Number 09-AT-018
Subject ATA SOLENOID DIAGNOSTIC TROUBLE CODES P0740, P0741, P0742, P0743, P0746,
P0748, P0750, P0755, P0760, P0765, P0770
This TSB supersedes TSB# 05-40-006 to change the test procedure (Step 5) and add additional
models.
DESCRIPTION:
Incorrect operation of the transaxle solenoids may result in the following symptoms:
^ Diagnostic Trouble Codes P0740, P0741, P0742, P0743, P0746, P0748, P0750, P0755, P0760,
P0765 or P0770 set
NOTE:
Do NOT replace the transaxle for solenoid codes listed as open/short. Instead, follow the repair
procedure shown below.
APPLICABLE VEHICLES:
NOTE:
Refer to TSB 09-AT-011 for 2007~10 (HD) Elantra Sedan and (FD)
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Bulletins: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 654
PARTS INFORMATION
REPAIR PROCEDURE:
1. Using a GDS, check for DTC in both the "Engine" and "Automatic Transaxle" menus. Record the
DTC and description.
^ Vehicle
^ "Actuation Test"
^ Press the "Start" button and listen for a solenoid sound and "Success" indication.
^ Fail: go to Step 3
^ Success: the wiring between the PCM/TCM currently has no open or short circuits. Go to Step 4.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 655
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MODEL Harman PM
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Refer to parts catalog
45305—330“
NOTE:
This test confirms the wiring harness currently does not have an open or short circuit. It does not
confirm the proper functioning of the solenoids under all conditions of heat and vibration or a
solenoid with an intermittent open/short condition.
3. If Step 2 shows an inoperative solenoid, visually check the wiring harness between the TCM and
transaxle for a damaged wire or a short circuit to ground. Disconnect the connectors to the
solenoids at the transaxle and the PCM/TCM and check for a bent pin or a pin not fully inserted into
the connector. If so, repair or replace the ECM control harness, P/N 914xx-xxxxx.
4. Check the harness inside the transaxle oil pan for a short circuit to ground. Replace the harness
if damage is found or if three or more solenoid DTC are found in Step 1. (Refer to TSB#04-40-015
for replacement instructions).
5. Refer to the DTC recorded in Step 1 and follow the repair procedure shown below:
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 656
DTD REPAIR PRDEEDURE
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10. Refer to the DTC recorded in Step 1 and replace the related solenoid according to the diagram
shown. Tighten the bolts to 4-5 lb.ft (50-70 kg.cm). Go to step 11.
11. Apply Permatex Ultra Gray Sealer or Hyundai Ultra Gray Gasket Sealer, P/N 00231-13800 to
the valve body cover and reinstall the cover. Tighten the bolts to 6-7 lb.ft (80-100 kg.cm).
12. Reinstall the radiator hoses and add ethylene glycol coolant to the radiator and overflow bottle.
Adjust the level according to the appropriate shop manual, "EM" section.
13. Add approximately five quarts of Hyundai SPIII ATF and check the level with the engine idling
in Neutral. Refer to TSB 06-40-016 and adjust the ATF level when the ATF is at normal operating
temperature (70-80°C, 158-176°F).
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page 657
14. Clear the codes and test drive the vehicle for two driving cycles (two key-on to key-off driving
cycles, including 1-2-3-4 upshifts and 4-3-2-1 downshifts). If the DTC returns, perform the repairs
shown above.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 08-AT-003 > May > 08 > A/T - Harsh/Delayed Upshift/Downshift
Control Module: All Technical Service Bulletins A/T - Harsh/Delayed Upshift/Downshift
Group: AUTOMATIC TRANSAXLE
Number: 08-AT-003
Model: 1999~ SONATA, 2001~06 ELANTRA, 2001~ SANTA FE & XG, 2003~ TIBURON, 2005~
TUCSON, 2006~ AZERA, 2007~ ENTOURAGE
This TSB supersedes TSB 07-40-010 to correct the labor time for OP Code 95440RP0 and
95440PQ0.
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed upshift or downshift,
follow the Diagnostic Procedure shown below.
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue with the diagnosis.
4. Attach the GDS and check for Diagnostic Trouble Codes in both the "Engine" and "Automatic
Transaxle" menu. If DTC's are found, repair according to the appropriate TSB or shop manual.
NOTE:
"Current Data"
^ "Shift position"
^ "Vehicle speed"
^ Select "PC Record" (on left of screen) and save the file.
"Items List" (top right of screen) and select: "Vehicle speed" and "Shift position".
PCM/TCM DIAGNOSIS:
Confirm the PCM or TCM commanded each gear: 1, 2, 3, 4 and 5 (if equipped): ^
If so, go to pages 3~6 and evaluate the upshift diagnosis for the related shift.
If not, exchange a PCM or TCM from a properly operating vehicle and test again to determine if the
PCM or TCM commanded each gear:
^ If the condition is not improved, go to page 3~6 and evaluate the upshift performance.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Underdrive Solenoid Duty"
and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 1-2 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The 2nd solenoid elapsed time is important; the shape of the graph is not.
['r':IL"Ir_II1II
I.'.l‘.l 'l'IH':I'I I
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "Underdrive Solenoid Duty", "Overdrive
Solenoid Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the OD solenoid elapsed time at the top right of the screen. If the 2-3 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive values":
NOTE:
The OD solenoid elapsed time is important; the shape of the graph is not.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Overdrive Solenoid
Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 3-4 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
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Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "Reduction Solenoid Duty", Low-Reverse
Solenoid Duty and "Shift Position".
^
Select the "+" or "-" button to choose 0.7 sec./Div or less.
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the LR solenoid elapsed time at the top right of the screen. If the 4-5 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION:
NOTE:
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 08-AT-003 > May > 08 > A/T - Harsh/Delayed Upshift/Downshift > Page 665
Warranty Claim requires input of DTC codes on all claims using Hi-Scan or GDS operations. If no
DTC code is identified by the Hi-scan or GDS, enter P0000 as a Scan Tool Test Code on the
Warranty Claim and attach printout from the Hi-scan or GDS to the Repair Order.
NOTE:
Printouts must be attached to all Repair Orders. Repair Orders without attached printouts are
subject to chargeback.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement
mm
ATF at nen'nel eperetfng temperature {158-212°F, FBI-1ETC}
‘ —
Control Module: All Technical Service Bulletins A/T - Harsh/Delayed Reverse or Drive Engagement
Group: TRANSAXLE
Number: 07-40-009-1
Models: 1999 - SONATA 2001-06 - ELANTRA 2001 - SANTA FE & XG 2003 - TIBURON 2005 -
TUCSON 2006 - AZERA 2007 - ENTOURAGE
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed shift into Drive or
Reverse, follow the Diagnostic Procedure shown below:
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
2. Perform the adaptive learning by shifting from Neutral to Reverse and Drive, stopping in each
gear for 5 seconds. Repeat 10 times.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue the diagnosis.
4. Check that idle speed is within specification. If not, inspect according to the appropriate shop
manual, "Fuel System Section".
5. Check the engine and transaxle mounting brackets and roll support brackets. If necessary,
replace the mounts.
6. Attach the GDS and check for Diagnostic Trouble Codes in both the "ENGINE" and
"AUTOMATIC TRANSAXLE" menus. If DTC are found, repair according to the appropriate TSB or
shop manual.
7. Attach the GDS and select "AUTOMATIC TRANSAXLE" menu, "CURRENT DATA" menu and
"FLUID TEMPERATURE SENSOR". Confirm the oil temperature sensor operates correctly as
shown. If not, inspect the oil temperature sensor according to TSB 04-40-016 or appropriate shop
manual.
8. Select "CURRENT DATA" and "TPS". Open and close the throttle and confirm the TPS
increases and decreases smoothly between approximately 0 - 100% duty.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 670
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9. Attach the GDS and select VIN and "A/T" "Current Data" and then select "Shift Position", "LR
Solenoid Duty" and "Underdrive Solenoid Duty" as shown.
10. Start the engine and move the shift lever between Neutral, Drive and Reverse, stopping 3-5
seconds in each gear.
11. Select "Record shown" at the top right of the screen. GDS will record up to 10 minutes data
prior to selecting "Record".
12. Select "PC Record" (top left of screen), then save file.
13. Select "Flight Record" and "Data Review", select the vehicle and open the file.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 671
. _'=' 1':I::!|-'iF¢I-"
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14. Select "Items List" (top right of screen), then select "Shift Position", "LR Solenoid Duty" and
"Underdrive Solenoid Duty".
16. Move the cursor to the start of the shift and "Left click".
17. Move the cursor to the end of the shift and "Right Click".
18. Read the Low & Reverse solenoid engagement time on the top right of the screen. If the P-R
shift requires more than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle
and follow TSB 06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
20. Select "Items List" (top right of screen), then select "Shift Position LR Solenoid Duty" and
"Underdrive Solenoid Duty".
22. Move the cursor to the start of the shift and "Left click".
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 672
1 . -. - - ‘Ru...|.|.l".l.-l-I.- I._J.-'l' —-_FI'TF'-
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IJWTJRIIT’? '-
ufiflfcfif"m5‘-Z'
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NDTE: Warranty Claim requlrea Input cf DTG ccclea an all claims ualng Hl-Scan
cr GEE cperatiene. H' nc DTL": cede ie identified by the Hi-ecan er GDS,
enter Fflflflfl aa a Scan cl Teat Code on the Warranty Claim and attach
plintcut frcrn the Hi-acan er GDS tn the Repair Grder.
NDTE: Frintcuta must be attached to all Repair Drdars. Repalr Orders wlthcut
attached printcuts are subject tc chargeback.
23. Move the cursor to the end of the shift and "Right Click".
24. Read the UD engagement time on the top right of the screen. If the P-D shift requires more
than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The UD solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > tnt1660906-03 > Sep > 06 > A/T, Engine Controls - ECM/TCM Reset/Relearn Procedure
Control Module: All Technical Service Bulletins A/T, Engine Controls - ECM/TCM Reset/Relearn
Procedure
MODEL: All
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This article provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. After the
following repairs have been completed, the PCM/TCM adaptive values must be reset in order to
provide optimum shift quality:
Adaptive values must be reset using procedure # 1 or # 2 according to model and model year (MY)
as shown below.
VEHICLES AFFECTED:
^ All
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P."
^ Select vehicle
press "ENTER"
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
NOTE:
Adaptive learning does not occur below the ATF temperature range shown.
WARRANTY INFORMATION:
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Control Module: All Technical Service Bulletins A/T Controls - PCM/TCM Reset/Relearn Adaptive
Values
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. Here are the procedures
necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. Afier the following
repairs have been completed, the PCM/TCM adaptive values must be reset in order to provide
optimum shift quality:
HI-SCAN PROCEDURE:
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > tnt1630506-01 > May > 06 > A/T Controls - PCM/TCM Reset/Relearn Adaptive Values > Page 684
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NOTE:
Adaptive learning does not occur below the ATF temperature range shown in next column:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 06-40-005 > Mar > 06 > A/T Controls - Reset and Relearn Adaptive Values
2.
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Control Module: All Technical Service Bulletins A/T Controls - Reset and Relearn Adaptive Values
Group: TRANSAXLE
Number: 06-40-005
Model: ALL
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
W WWW
WWW
2m-
2005 MT-v
2005 MY-
BIG! IE EPIIII
THREE! I DELI RPI'I
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1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
"" - 4" 1:m :1 41 11
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 06-40-005 > Mar > 06 > A/T Controls - Reset and Relearn Adaptive Values > Page 690
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After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR" "ACCEL. POS. S". or "ACCEL PEDAL 1
VOLT", depending on model).
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi- Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the accelerator pedal steady at a throttle position
sensor value of 1.45-1.75v during several 1-2-3-4 upshifts. Repeat until normal gear transitions
occur.
NOTE:
Adaptive learning does not occur below the ATF temperature range previously shown.
WARRANTY INFORMATION:
Control Module: All Technical Service Bulletins A/T - No Movement in 'DRIVE' or 'REVERSE'
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DIG are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
m
h
E
5
I
m
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
LE BflLlHflID BUT!
[III HELENE!!! BUT!
EHD BELEHIIIII DUI!
02D BflLlHflIll BUT!
BED EDLEHHID DUI!
flIL IMPEBHIUEE
SHIFT POEITIDH
8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 697
1. 2 CURRENT IH-‘I‘I'FI
l H H H - H ‘ H
an EDIE”!!! Ell"!
fllL I w m m
'1
SHIFT PflSITIfl'I
"5'1 T: T.. T'I1'Z T L Flt-T F: FH-J.
l-‘IH I - I m l m l m l m -
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 698
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Control Module: > 07-36-006 > Sep > 07 > Engine Controls - Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - Low
Power/MIL ON/DTC P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
‘TFI
J '-'II | : | - u - ' - . l r r I r - - ! . - ; + | I I I ' I
1 GDJ .
."’:.-_L-J.|_.I'..'.-.. T [Ilagnmut
. ' "
.-..I.'.:_J .‘.I.J...u..:..uji
,
JLJLHLJ' ‘
awn-an Inn-r
aflml'rf _ -- -;--' ' 'I.'|'H 5|."|'-l-IlTHP-lfill'i'flli'l'r'." 3 I'm 1‘7"": Hm w "WW”:
a mu: El
H “in hip lctinn
j
a Frau“ Frlma j
m m w m m : m r
l m h | “ I
Huh-Im- mun-£1 cum
h u m - mIii-I III
‘ 1313mm: U luluhuh-I Tun-pm Ian— II
JED ill-11::- I'm:I ' M - fl I.-
Lnn| 'l— Fufl 'l'I-I-llfli -l.l
iI-I-I T.- F-ufl T i l d ! ‘ [I
l ml T H Fufl Ink-Bud! fl
_ H l fl I I I - h iFull-lll l l l l t fl..-
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Example GDS DTC screen shown.
DP CASUAL CUBE
firljflDEL 01’ NAME TIME PART I
NATURE CAUSE
327m 3mm
msmnw DIAGHDEIE
3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Control Module: > 10-EE-002 > Jul > 10 > Engine Controls - MIL ON/DTC P2138/P2127/P2122/P2106 > Page 717
I Pragarutiurl It Lllaquii-s 'faiE-a-iuh'lkhliufi . I , LéEEITI'
'|"r-‘-' " ' WEEK; BDMTNIiFHIDDfiI'E- 3 3"II'E EIIJHC l'i'E-lL'JII E-IEIIEJGEIJMIIDfl'l-B
E]
L-II-FIILII'ILI'J 5. lag“:-
' fl DTC
| IA
BEE"! IHEPEEfifll'I Fr.:p::.,..ull [IT-:1. F.-r:r:.'r: I'm-m: r_,-3"'_: Lima--5 EFJ:.'_- Effigy: LITE:
I [I I.
DTC Ana lysis
L‘uDTc mum H131 W I Fulfil I m m n E m :Ill-Ilium
lmp1”! ThnflIwPed-al Push PHI! 11m”: Adan-Ilium!Ewan-Fm:Lllnlcl Pun
Q PINE “mu. Actuuur c:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Control Module: > 07-36-006 > Sep > 07 > Engine Controls - Low Power/MIL ON/DTC P2138/P2127/P2122 > Page 723
‘TFI
J '-'II | : | - u - ' - . l r r I r - - ! . - ; + | I I I ' I
1 GDJ .
."’:.-_L-J.|_.I'..'.-.. T [Ilagnmut
. ' "
.-..I.'.:_J .‘.I.J...u..:..uji
,
JLJLHLJ' ‘
awn-an Inn-r
aflml'rf _ -- -;--' ' 'I.'|'H 5|."|'-l-IlTHP-lfill'i'flli'l'r'." 3 I'm 1‘7"": Hm w "WW”:
a mu: El
H “in hip lctinn
j
a Frau“ Frlma j
m m w m m : m r
l m h | “ I
Huh-Im- mun-£1 cum
h u m - mIii-I III
‘ 1313mm: U luluhuh-I Tun-pm Ian— II
JED ill-11::- I'm:I ' M - fl I.-
Lnn| 'l— Fufl 'l'I-I-llfli -l.l
iI-I-I T.- F-ufl T i l d ! ‘ [I
l ml T H Fufl Ink-Bud! fl
_ H l fl I I I - h iFull-lll l l l l t fl..-
-Emm M "
HEU EEEE null -nan : W
Example GDS DTC screen shown.
DP CASUAL CUBE
firljflDEL 01’ NAME TIME PART I
NATURE CAUSE
327m 3mm
msmnw DIAGHDEIE
3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Component Locations
Detail
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Component Locations > Page 727
PHOTflJfl e
. 3.3L
if.
Control Module: Connector Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Shift Interlock Control Module: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK'
Shift Interlock Control Module: Customer Interest A/T - Can't Shift Into/Out Of 'PARK'
Number: 06-40-008-1
Subject: AUTOMATIC TRANSAXLE SHIFT LEVER WILL NOT SHIFT OUT OF PARK
DESCRIPTION:
If the shift lever of a 2006 Sonata, Azera or 2007 Santa Fe, Elantra or Entourage vehicle does not
shift into or out of Park, please follow the repair procedure:
REPAIR PROCEDURE:
^ Vehicle
^ "Automatic Transaxle",
^ "Current Data"
^ Brake Switch"
2. Confirm the "Brake Switch" reads "ON" when the brake pedal is depressed. If not, check the
brake switch clearance according to the related shop manual. If the clearance is within
specification, install a known-good brake switch:
^ Check fuses and related wiring as shown in the related E/M, page 5D452-2.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Shift Interlock Control Module: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 736
Remove
nuts
HIM H'HLEVII
Emir." _
-'IT'H P - E ' I ‘ L C C K
- ':- mmmr
2006 - SONATA
^ Refer to the 2006 or 2007 Sonata Shop Manual, page BD-52 and remove the center panel.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
2006 - AZERA:
^ Refer to the 2006 or 2007 Azera Shop Manual, page BD-62 and remove the glove box.
^ Remove the two nuts and disconnect the M76 connector to the ATM key lock control module. Go
to "Test Procedure".
2007 - ENTOURAGE:
^ Refer to the 2007 Entourage Shop Manual, page BD-61 and remove the floor console cover.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Shift Interlock Control Module: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 737
2007 - SANTA FE:
^ Refer to the 2007 Santa Fe Shop Manual, page BD-63 and remove the center fascia panel.
^ Disconnect the M02 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Santa Fe ETM, page CL- 11, photo 61 for clarity).
2007 - ELANTRA
^ Refer to the 2007 Elantra Shop Manual, page BD-51 and remove the lower panel.
^ Disconnect the M12 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Elantra ETM, page CL-7, photo 38 for clarity).
TEST PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Shift Interlock Control Module: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 738
EflflTH ELANTRA
Ftaplau-a ATM
n- 9535!]-
Qfiflfifl-
EI-lflflfl
“NEH
W34: Innparafiva
"U15; PIEHJI' ml'llflEf-l E: Eil'flLfl'L flpfll'l Eir'Guil
3. Turn the ignition switch to the "ON" position. Check voltage at the pins according to table. If the
voltages are correct, replace the ATM key lock control module.
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Shift Interlock Control Module: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK'
Shift Interlock Control Module: All Technical Service Bulletins A/T - Can't Shift Into/Out Of 'PARK'
Number: 06-40-008-1
Subject: AUTOMATIC TRANSAXLE SHIFT LEVER WILL NOT SHIFT OUT OF PARK
DESCRIPTION:
If the shift lever of a 2006 Sonata, Azera or 2007 Santa Fe, Elantra or Entourage vehicle does not
shift into or out of Park, please follow the repair procedure:
REPAIR PROCEDURE:
^ Vehicle
^ "Automatic Transaxle",
^ "Current Data"
^ Brake Switch"
2. Confirm the "Brake Switch" reads "ON" when the brake pedal is depressed. If not, check the
brake switch clearance according to the related shop manual. If the clearance is within
specification, install a known-good brake switch:
^ Check fuses and related wiring as shown in the related E/M, page 5D452-2.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Shift Interlock Control Module: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page
744
Remove
nuts
HIM H'HLEVII
Emir." _
-'IT'H P - E ' I ‘ L C C K
- ':- mmmr
2006 - SONATA
^ Refer to the 2006 or 2007 Sonata Shop Manual, page BD-52 and remove the center panel.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
2006 - AZERA:
^ Refer to the 2006 or 2007 Azera Shop Manual, page BD-62 and remove the glove box.
^ Remove the two nuts and disconnect the M76 connector to the ATM key lock control module. Go
to "Test Procedure".
2007 - ENTOURAGE:
^ Refer to the 2007 Entourage Shop Manual, page BD-61 and remove the floor console cover.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Shift Interlock Control Module: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page
745
2007 - SANTA FE:
^ Refer to the 2007 Santa Fe Shop Manual, page BD-63 and remove the center fascia panel.
^ Disconnect the M02 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Santa Fe ETM, page CL- 11, photo 61 for clarity).
2007 - ELANTRA
^ Refer to the 2007 Elantra Shop Manual, page BD-51 and remove the lower panel.
^ Disconnect the M12 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Elantra ETM, page CL-7, photo 38 for clarity).
TEST PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Shift Interlock Control Module: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page
746
'DEPHESSED
NGTE: * Pin #6 = fly far Entaurage
W34: Innparafiva
"U15; PIEHJI' ml'llflEf-l E: Eil'flLfl'L flpfll'l Eir'Guil
3. Turn the ignition switch to the "ON" position. Check voltage at the pins according to table. If the
voltages are correct, replace the ATM key lock control module.
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Shift Interlock Control Module > Component Information > Technical Service Bulletins > Page 747
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and
Instructions
THEE: -
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. - I - ...|._......L._... .
..I—I....i-rpr. .
p ..
H...H.H1..H....
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 755
E .
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 756
35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 757
.—
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 758
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 760
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Instructions > Page 761
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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Instructions > Page 762
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Instructions > Page 763
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Instructions > Page 764
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Instructions > Page 765
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Instructions > Page 766
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Testing and Inspection > Rear Window Defogger Relay
Heated Glass Element Relay: Testing and Inspection Rear Window Defogger Relay
INSPECTION
1. Disconnect the negative (-) battery terminal. 2. Remove the junction box. 3. Check for continuity
between the terminals. 4. There should be continuity between the No.2 in the I/P-G and No.7
terminal in the I/P-C when power and ground are connected to the No.2
5. There should be no continuity between the No.2 terminal in the I/P-G and No.7 terminal in the
I/P-C when power is disconnected.
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Relay > Component Information > Testing and Inspection > Rear Window Defogger Relay > Page 772
Heated Glass Element Relay: Testing and Inspection Windshield Deicer Relay
INSPECTION
1. Disconnect the negative (-) battery terminal. 2. Remove the junction box. 3. Check for continuity
between the terminals. 4. There should be continuity between the No.2 in the I/P-G and No.8
terminal in the I/P-K when power and ground are connected to the No.2
5. There should be no continuity between the No.2 terminal in the I/P-G and No.8 terminal in the
I/P-K when power is disconnected.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Locations
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Diagrams > Diagram Information and Instructions
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Power Window Relay: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Component Information > Diagrams > Diagram Information and Instructions > Page 784
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Component Information > Diagrams > Diagram Information and Instructions > Page 785
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Component Information > Diagrams > Diagram Information and Instructions > Page 786
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Component Information > Diagrams > Diagram Information and Instructions > Page 787
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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Component Information > Diagrams > Diagram Information and Instructions > Page 791
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Component Information > Diagrams > Diagram Information and Instructions > Page 793
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Diagrams > Page 796
Power Window Relay: Testing and Inspection
INSPECTION
1. Disconnect the negative (-) battery terminal. 2. Remove the junction box. 3. Check for continuity
between the terminals. 4. There should be continuity between the No.1 in the I/P-G and No.12
terminal in the I/P-A when power and ground are connected to the No.1
5. There should be no continuity between the No.1 terminal in the I/P-G and No.12 terminal in the
I/P-A when power is disconnected.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions
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Windshield Washer Control Module: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 802
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 805
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 806
l
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Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 807
fi
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3 I I I - l i d “ fi l l fl l h l l - I ' I P - I fl u — l
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 808
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 810
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 811
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 812
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 813
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 814
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 815
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 816
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions
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Wiper Control Module: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 821
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 824
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 825
l
l
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Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 826
fi
1...:
3 I I I - l i d “ fi l l fl l h l l - I ' I P - I fl u — l
a
Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 827
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 829
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 830
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 831
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 832
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 833
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 834
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 835
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
E. FIJI pump M
2+ Han-i lump why {High} 1'. Whur rally
3. Stan rally E. Alr nurtliiminn relay
4-. EfiE—I curtrd relay 9. Frunt flag mlay
5. NT rainy 1D. Hum Inlay
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions
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Wiper Relay: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 841
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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tha color uf 1h: calm uf
backgrmfl‘rd Stripe
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unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Component Information > Diagrams > Diagram Information and Instructions > Page 844
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 845
l
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Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 846
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 847
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 849
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Component Information > Diagrams > Diagram Information and Instructions > Page 850
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 851
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 852
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 853
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Component Information > Diagrams > Diagram Information and Instructions > Page 854
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Component Information > Diagrams > Diagram Information and Instructions > Page 855
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood
Sensor/Switch (For Alarm): > 09-BE-026 > Sep > 09 > Antitheft System - Alarm System Self-Activates
Hm-flflhmh i l l l l i Langlh m m
by 2.5 mm
Hood Sensor/Switch (For Alarm): Customer Interest Antitheft System - Alarm System
Self-Activates
Group BODY
Number 09-BE-026
DESCRIPTION:
The vehicle alarm system may intermittently sound due to light contact of the hood switch pad with
the hood switch.
This bulletin provides instructions to replace the hood switch pad with a revised part.
PARTS INFORMATION
SERVICE PROCEDURE
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood
Sensor/Switch (For Alarm): > 09-BE-026 > Sep > 09 > Antitheft System - Alarm System Self-Activates > Page 866
3. Close the hood and press the LOCK button on the transmitter. Verify that all the doors lock and
the hazard lights flash one time.
4. Press the LOCK button on the transmitter two times to confirm the "Horn Answer Back" feature
is operational.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Hood Sensor/Switch (For Alarm): > 09-BE-026 > Sep > 09 > Antitheft System - Alarm System Self-Activates
Hm-flflhmh i l l l l i Langlh m m
by 2.5 mm
Hood Sensor/Switch (For Alarm): All Technical Service Bulletins Antitheft System - Alarm System
Self-Activates
Group BODY
Number 09-BE-026
DESCRIPTION:
The vehicle alarm system may intermittently sound due to light contact of the hood switch pad with
the hood switch.
This bulletin provides instructions to replace the hood switch pad with a revised part.
PARTS INFORMATION
SERVICE PROCEDURE
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Hood Sensor/Switch (For Alarm): > 09-BE-026 > Sep > 09 > Antitheft System - Alarm System Self-Activates > Page 872
3. Close the hood and press the LOCK button on the transmitter. Verify that all the doors lock and
the hazard lights flash one time.
4. Press the LOCK button on the transmitter two times to confirm the "Horn Answer Back" feature
is operational.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 873
'H‘LH'HIJIT
"al'nmed
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 874
2. Check for continuity between the terminals and ground according to the table
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Pedal Positioning Switch > Component Information > Locations
PHDTDJ!
'I
#4:: I n “
( 4 : 1 1 ? "
-'- 4 I linumunnnu: “g T
'fi .--.. rum fll‘I‘EH "I.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Fuel Door Switch >
Component Information > Testing and Inspection
INSPECTION
1. Remove the front door trim panel. 2. Check the switch for continuity between the No.1 and No.2
terminals.
Hm-flflhmh i l l l l i Langlh m m
by 2.5 mm
Hood Sensor/Switch (For Alarm): Customer Interest Antitheft System - Alarm System
Self-Activates
Group BODY
Number 09-BE-026
DESCRIPTION:
The vehicle alarm system may intermittently sound due to light contact of the hood switch pad with
the hood switch.
This bulletin provides instructions to replace the hood switch pad with a revised part.
PARTS INFORMATION
SERVICE PROCEDURE
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood
Sensor/Switch (For Alarm): > 09-BE-026 > Sep > 09 > Antitheft System - Alarm System Self-Activates > Page 891
3. Close the hood and press the LOCK button on the transmitter. Verify that all the doors lock and
the hazard lights flash one time.
4. Press the LOCK button on the transmitter two times to confirm the "Horn Answer Back" feature
is operational.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Hood Sensor/Switch (For Alarm): > 09-BE-026 > Sep > 09 > Antitheft System - Alarm System Self-Activates
Hm-flflhmh i l l l l i Langlh m m
by 2.5 mm
Hood Sensor/Switch (For Alarm): All Technical Service Bulletins Antitheft System - Alarm System
Self-Activates
Group BODY
Number 09-BE-026
DESCRIPTION:
The vehicle alarm system may intermittently sound due to light contact of the hood switch pad with
the hood switch.
This bulletin provides instructions to replace the hood switch pad with a revised part.
PARTS INFORMATION
SERVICE PROCEDURE
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Hood Sensor/Switch (For Alarm): > 09-BE-026 > Sep > 09 > Antitheft System - Alarm System Self-Activates > Page 897
3. Close the hood and press the LOCK button on the transmitter. Verify that all the doors lock and
the hazard lights flash one time.
4. Press the LOCK button on the transmitter two times to confirm the "Horn Answer Back" feature
is operational.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 898
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 899
2. Check for continuity between the terminals and ground according to the table
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning
Switch > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Locations
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Components Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection > Front
3. Check for continuity between the terminals in each switch position according to the table.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection > Front > Page 908
3. Check for continuity between the terminals in each switch position according to the table.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection > Front > Page 909
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Power Door Lock Switch: Testing and Inspection Power Door Lock Switch
1. Disconnect the negative (-) battery terminal. 2. Remove the front door trim panel.
4. Check for continuity between the terminals in each switch position according to the table.
1. Disconnect the negative (-) battery terminal. 2. Remove the front door trim panel.
4. Check for continuity between the terminals in each switch position according to the table
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Component Locations
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Component Locations > Page 915
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions
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Power Mirror Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 918
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 921
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 922
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 923
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 924
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 926
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 927
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 928
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 929
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 930
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 931
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 932
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 933
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Circuit Diagram
For information regarding diagrams for this component, please refer to Mirrors diagrams. See:
Body and Frame/Mirrors/Diagrams/Electrical Diagrams
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams > Page 934
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Power Mirror Switch: Testing and Inspection
INSPECTION
1. Disconnect the negative (-) battery terminal. 2. Remove the front door trim panel.
4. Check for continuity between the terminals in each switch position according to the table.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Technical Service Bulletins > Interior - Revised Power Seat Switch Schematic
Power Seat Switch: Technical Service Bulletins Interior - Revised Power Seat Switch Schematic
DESCRIPTION: This TSB provides a revised power seat schematic for the 2006 Sonata ETM
(Electrical Troubleshooting Manual), and the corresponding revision for the power seat switch
testing chart in the Shop Manual.
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Technical Service Bulletins > Interior - Revised Power Seat Switch Schematic > Page 942
88521-OA001 V-fi vehicles with the first 3 digits of the VIN “5N?”
88521-3K001 1-4 vehicles with the first 3 digits ef the VIN “KMH”
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Power Seat Switch: Technical Service Bulletins Interior - Power Seat Switch Part Numbers
Group: ELECTRICAL
Number: 05-90-011
DESCRIPTION
If the driver's side power seat switch requires replacement, please use the following part numbers.
This switch is available as a separate part from the driver's side power seat track assembly.
WARRANTY INFORMATION:
CGHPDHEHT LOCATION
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Component Locations > Page 945
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2005.
INSPECTION
With the power seat switch in each position, make sure that continuity exists between the terminals
below. If continuity is not as specified, replace the switch.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate
Lock Switch > Component Information > Locations
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate
Lock Switch > Component Information > Locations > Page 950
1. Remove the front door trim panel. 2. Check the switch for continuity between the No.3 and No.4
terminals.
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations > Page 954
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INSPECTION
2. Remove the seat warmer switch from the floor console upper cover with scraper.
3. Check for continuity between the terminals in each switch position according to the table.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Component Locations
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof
Switch > Component Information > Locations > Component Locations > Page 959
SUNROOF SWITCH
INSPECTION
2. Open the sunglass case cover from the overhead console then remove the 2 screws (B) holding
the overhead console.
3. Disconnect the connector then remove the overhead console lamp assembly from the headliner.
Check for continuity between the terminals. If the
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Locations > Component Locations > Page 965
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Trunk / Liftgate Switch: Connector Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
1. Remove the connector(A) from the switch located at the brake fluid reservoir(B).
2. Verify that continuity exists between switch terminals 1 and 2 while pressing the switch (float)
down with a rod.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Locations > Page 974
The parking brake switch (A) is a pulling type. It is located under the parking brake lever. To adjust,
move the switch mount up and down with the parking brake lever released all the way.
1. Check that there is continuity between the terminal and switch body with the switch ON (Lever is
pulled).
2. Check that there is no continuity between the terminal and switch body with the switch OFF
(Lever is released).
If continuity is not as specified, replace the switch or inspect its ground connection.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Testing and Inspection
INSPECTION
1. Remove the floor console and the connector (B) from the switch (A). 2. Inspect the continuity
between (-) terminal and the ground.
^ When the brake lever is pulled, there should be the continuity between them.
^ When the brake lever is released, there should be no continuity between them.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > ABS/TCS - Steering Angle Sensor
Centering Procedure
ELI: £1211!d
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Steering Angle Sensor Centering
Procedure
DESCRIPTION:
All 2006 MY Sonata vehicles are equipped with Electronic Stability Control (ESC). The ESC system
contains a steering angle sensor which measures the amount and rate of steering wheel input. The
steering angle sensor is used by the ESC to determine if brake or engine torque interventions
should be activated to help the driver.
The steering angle sensor requires calibration whenever the following occurs:
This article provides a procedure to recalibrate the steering angle sensor using the Hi-Scan Pro.
PROCEDURE:
1. Vehicle alignment must meet the following requirements before steering angle calibration can be
started.
^ Roll the vehicle forward and backward on a flat level surface prior to calibration.
NOTE:
Leave the ignition key in the "OFF" position before starting the following procedure.
2. Attach the Data Link Connector (DLC) cable to the Hi-Scan Pro main body and securely tighten
two bolts.
3. Plug the DLC cable into the 16 pin data link connector.
4. Turn the ignition switch to the "ON" position (do not start the engine).
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10. Press ENTER.
11. Select "Rest".
WARRANTY INFORMATION:
Applicable warranty
coverage applies.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 984
CDHPG'NENTS
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The steering angle speed sensor detects the angle of the steering wheel in order to which direction
a user chooses. The sensor is detached on the MFS (Multi-Function Switch) under the steering
wheel.
MEASURING PRINCIPLE
A non contact, analog angle sensor carrying out absolute measuring by the use of the
Anisotropic-Magneto-Resistive effect (AMR). Measuring of the absolute angle by means of a
toothed measuring gear with magnetic properties in combination with different ratios.
Corresponding AMR elements that change their electrical resistance according to the magnetic
field direction detect the angle position of the measuring gears. A micro-controller decodes the
measured voltage signals after A/D converting with the help of a mathematical function. Output of
the digital angle value and velocity via CAN-interface.
SPECIFICATION
SPECIFICATION
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 991
Traction Control Switch: Description and Operation
ESC SWITCH
DESCRIPTION
1. The ESC OFF switch is for the user to turnoff the ESC system. 2. The ESC OFF lamp is on
when ESC OFF switch is engaged.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 992
ESC SWITCH
INSPECTION
1. Remove the ESC OFF switch from the switch panel on the crash pad of the driver's side.
1. Check the continuity between the switch terminals as the ESC OFF switch is engaged.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > ABS/TCS - Wheel Speed Sensor Manual
Corrections
Wheel Speed Sensor: Technical Service Bulletins ABS/TCS - Wheel Speed Sensor Manual
Corrections
Group: CHASSIS
Number: 05-50-008
DESCRIPTION:
The 2006 Sonata Shop Manual (page BR-79) contains incorrect information for the wheel speed
sensor power supply circuit inspection diagram.
Terminal "2" is the signal wire. The voltage between terminal "2" and chassis ground will fluctuate
between a high of 0.89~1.26V and a low of 0.44~0.63V Please note the changes below.
2. Measure voltage between terminal "1" of the vehicle harness wheel speed sensor harness
connector and chassis ground.
3. Specification: approx. B+
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Page 997
This article has been updated by technical service bulletin (TSB) 05-50-008 dated August 2005.
The 2006 Sonata Shop Manual (page BR-79) contains incorrect information for the wheel speed
sensor power supply circuit inspection diagram. The correct terminal is terminal 1. Terminal 2 is the
signal wire.
Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.
Service standard
Output voltage When measuring with an oscilloscope: Min. 120mVp.p (at 2.75 Km/h)
Note: -
Voltage to terminal 1 will be approximately zero if a DTC code is set for the wheel speed sensor
being tested.
- The voltage between terminal 2 and chassis ground will fluctuate between a high of 0.89 ~ 1.26V
and a low of 0.44 ~ 0.63V.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Component Locations
CWPDHEHTE £15m
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Wheel Speed Sensor: Connector Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Wheel Speed Sensor: Initial Inspection and Diagnostic Overview
This article has been updated by technical service bulletin (TSB) 05-50-008 dated August 2005.
The 2006 Sonata Shop Manual (page BR-79) contains incorrect information for the wheel speed
sensor power supply circuit inspection diagram. The correct terminal is terminal 1. Terminal 2 is the
signal wire.
Inspection
1. Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.
Service standard
2. Connect a voltmeter between the wheel speed sensor terminals, and measure the voltage by
turning the wheel.
1. Turn ignition "ON" & engine "OFF". 2. Measure voltage between terminal "1" of the vehicle
harness wheel speed sensor harness connector and chassis ground. 3. Specification: approx. B+
Note: -
Voltage to terminal 1 will be approximately zero if a DTC code is set for the wheel speed sensor
being tested.
- The voltage between terminal 2 and chassis ground will fluctuate between a high of 0.89 ~ 1.26V
and a low of 0.44 ~ 0.63V.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1004
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Wheel Speed Sensor: Component Tests and General Diagnostics
Front
INSPECTION
1. Measure the output voltage between the terminal of the wheel speed sensor and the body
ground.
CAUTION: In order to protect the wheel speed sensor, when measuring output voltage, a 75 Ohms
resistor must be used as shown.
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of
the output voltage as shown below.
Rear
INSPECTION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1005
CAUTION: In order to protect the wheel speed sensor, when measuring output voltage, a 75 Ohms
resistor must be used as shown.
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of
the output voltage as shown.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front
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Wheel Speed Sensor: Service and Repair Front
COMPONENTS
REMOVAL
1. Remove the front wheel speed sensor mounting bolt (A). 2. Remove the front wheel guard.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front > Page 1008
3. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector
(A).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Front > Page 1009
Wheel Speed Sensor: Service and Repair Rear
COMPONENTS
REMOVAL
2. Remove the rear seat side pad then disconnect the rear wheel speed sensor connector (A).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Component Locations
CDHPG'NENTS
Yaw-late I Iataral E m r
F E W warnlng lamp
EEC UFF Warring lamp
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 1016
SPEEIFIEATIDH
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DESCRIPTION
1. The yaw-rate & lateral G sensor is applied for the ESC system. 2. The yaw-rate is the angular
velocity, when a vehicle turns a corner, and the lateral G is the acceleration to move a vehicle out of
the way when
cornering.
SPECIFICATION
SPECIFICATION
OUTPUT CHARACTERISTIC
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 1017
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Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Specifications >
Page 1024
DESCRIPTION
1. Water temperature sensor(A) is located at the heater unit. 2. It detects coolant temperature. Its
signal is used for cold engine lockout control. When the driver operates the heater before the
engine is warmed
up, the signal from sensor causes the heater control unit to reduce blower motor speed until
coolant temperature reaches the threshold value.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information > Specifications >
Page 1025
INSPECTION
1. Ignition "OFF". 2. Disconnect water temperature sensor connector. 3. Using the multi-tester,
Measure resistance between terminal "1" and "2" of water temperature sensor. 4. If the measured
resistance is not specification, substitute with a known-good water temperature sensor and check
for proper operation.
REPLACEMENT
2. Pull out the passenger's crash pad center low cover (A). 3. Remove the under cover after
loosening 2 screws. 4. Disconnect the connector (A) of water temperature sensor.
5. Pull the water temperature sensor(B) out at the heater unit with the stopper (C). 6. Install in the
reverse order of removal.
NOTE: Take care that wire of water temperature sensor is not to be damaged.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1030
HI'EFIEHD
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1031
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1032
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1033
DESCRIPTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1034
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DESCRIPTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1035
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Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1040
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1043
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1044
35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1045
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1046
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1048
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1049
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1050
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1051
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1052
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1053
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information
and Instructions > Page 1054
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 1055
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1. Using an ohmmeter, measure the resistance between the terminal 2 and ground.
2. If the resistance value is not as shown in the table, replace the temperature sender.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise
Control > Component Information > Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions
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Cruise Control Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1064
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1067
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1068
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1069
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1070
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1072
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1073
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1074
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1075
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1076
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1077
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1078
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1079
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For information regarding diagrams for this component, please refer to Powertrain Management
diagrams. See: Diagrams/Electrical Diagrams/Powertrain Management/System Diagram/System
Detailed Diagrams/Wiring Diagram Index
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions
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Oil Pressure Sender: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1086
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1089
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1090
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1091
fi
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1092
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1094
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1095
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1096
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1097
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1098
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1099
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1100
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender >
Component Information > Diagrams > Page 1101
INSPECTION
1. Check the continuity between the terminal and the body with an ohmmeter.
2. Check the continuity between the terminal and the body when the fine wire is pushed.
If there is continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch
is operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch,
Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Temperature Sensor/Switch: >
09-EM-005 > Jul > 09 > Engine Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor/Switch: Customer Interest Engine Controls - Oil Temperature Sensor Oil
Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
^ Torque Wrench
^ Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch,
Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Temperature
Sensor/Switch: > 09-EM-005 > Jul > 09 > Engine Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor/Switch: All Technical Service Bulletins Engine Controls - Oil Temperature
Sensor Oil Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
^ Torque Wrench
^ Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch,
Engine > Component Information > Technical Service Bulletins > Page 1117
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Technical Service Bulletins > A/C - Ambient Air Temperature Sensor
Replacement
Ambient Temperature Sensor / Switch HVAC: Technical Service Bulletins A/C - Ambient Air
Temperature Sensor Replacement
DESCRIPTION:
On some vehicles the ambient temperature displayed on the climate controller may differ from the
actual outside temperature by more than 5-10°F. An updated ambient temperature sensor is
available to improve this condition. This article provides the procedure to install the updated
ambient temperature sensor located in front of the radiator/condenser.
VEHICLES AFFECTED:
PARTS INFORMATION
^ The current part number will continue to be used with the updated part.
^ To determine if the vehicle has a factory installed or an updated part, refer to the photos.
REPLACEMENT PROCEDURE:
bolt.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Technical Service Bulletins > A/C - Ambient Air Temperature Sensor
Replacement > Page 1123
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5. Reset the A/C control head after ambient temperature sensor replacement.
a. Azera - Remove for 15 seconds the Power Connector Fuse (30 amp) from the passenger
compartment junction block and replace.
b. Sonata - Remove for 15 seconds the Power Connector 2 Fuse (15 amp) from the passenger
compartment junction block and replace.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Technical Service Bulletins > Page 1124
SPEEIFIEA'I'IDH
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Component Locations
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Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Component Locations > Page 1127
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 1128
DESCRIPTION
1. The ambient temperature sensor is located at the front of the condenser and detects ambient air
temperature. It is a negative type thermistor;
resistance will increase with lower temperature, and decrease with higher temperatures.
2. The sensor output will be used for discharge temperature control, temperature regulation door
control, blower motor level control, mix mode
NOTE: -
If the ambient temperature is below 2.0 degrees C (35.6 degrees F), the A/C compressor will be
stopped.
INSPECTION
1. Ignition "OFF". 2. Disconnect ambient temperature sensor connector. 3. Check the resistance of
ambient temperature sensor between terminals 1 and 2 whether it is changed by changing
temperature of the ambient
temperature sensor.
REPLACEMENT
1. Disconnect the negative (-) battery terminal. 2. Remove the front bumper.
3. Remove the ambient temperature sensor(A) after loosening the mounting bolt. 4. Installation is
the reverse order of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Specifications
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Specifications > Page 1134
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Specifications > Page 1135
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DESCRIPTION
2. The sensor contains a thermistor which measures the temperature of the inside. The signal,
decided by the resistance value which changes in
accordance with perceived inside temperature, is delivered to heater control unit and according to
this signal the control unit regulates incar temperature to intended value.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Specifications > Page 1136
INSPECTION
3. Using the multi-tester, Measure resistance between terminal "2" and "4" of in-car sensor.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Specifications > Page 1137
REPLACEMENT
1. Disconnect the negative (-) battery terminal. 2. Remove the lower crash panel (A). 3. Disconnect
the connector of in-car sensor.
4. Loosen the mounting screws (B) and then remove the in-car sensor (C). 5. Installation is the
reverse order of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Quality Sensor <--> [Climate
Control Exhaust Gas Sensor] > Component Information > Specifications
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Quality Sensor <--> [Climate
Control Exhaust Gas Sensor] > Component Information > Specifications > Page 1141
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Quality Sensor <--> [Climate
Control Exhaust Gas Sensor] > Component Information > Specifications > Page 1142
Air Quality Sensor: Description and Operation
DESCRIPTION
1. A.Q.S is located at center support in front of the engine radiator, and detects hazardous
elements in ambient air providing output signal to control. 2. It will detect sulfurous acid gas, carbon
dioxide, carbon monoxide, hydrocarbon and allergen.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Quality Sensor <--> [Climate
Control Exhaust Gas Sensor] > Component Information > Specifications > Page 1143
INSPECTION
REPLACEMENT
1. Disconnect the negative (-) battery terminal. 2. Remove the front bumper.
3. Remove the AQS sensor (A) after loosening the mounting screws. 4. Install in the reverse order
of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Coolant Temperature Sensor /
Switch HVAC > Component Information > Specifications
SPECIFIEATI‘DH
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Coolant Temperature Sensor /
Switch HVAC > Component Information > Specifications > Page 1149
DESCRIPTION
1. Water temperature sensor(A) is located at the heater unit. 2. It detects coolant temperature. Its
signal is used for cold engine lockout control. When the driver operates the heater before the
engine is warmed
up, the signal from sensor causes the heater control unit to reduce blower motor speed until
coolant temperature reaches the threshold value.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Coolant Temperature Sensor /
Switch HVAC > Component Information > Specifications > Page 1150
INSPECTION
1. Ignition "OFF". 2. Disconnect water temperature sensor connector. 3. Using the multi-tester,
Measure resistance between terminal "1" and "2" of water temperature sensor. 4. If the measured
resistance is not specification, substitute with a known-good water temperature sensor and check
for proper operation.
REPLACEMENT
2. Pull out the passenger's crash pad center low cover (A). 3. Remove the under cover after
loosening 2 screws. 4. Disconnect the connector (A) of water temperature sensor.
5. Pull the water temperature sensor(B) out at the heater unit with the stopper (C). 6. Install in the
reverse order of removal.
NOTE: Take care that wire of water temperature sensor is not to be damaged.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Specifications
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Specifications > Page 1155
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Evaporator Temperature Sensor / Switch: Locations
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Specifications > Page 1156
Evaporator Temperature Sensor / Switch: Description and Operation
DESCRIPTION
The evaporator temperature sensor will detect the evaporator core temperature and interrupt
compressor relay power in order to prevent evaporator freezing by excessive cooling.
INSPECTION
1. Ignition "ON". 2. Turn on the A/C switch. 3. Disconnect evaporator temperature sensor.
4. Using the multi-tester, Measure resistance between terminal "1" and "2" of evaporator
temperature sensor. 5. If the measured resistance is not specification, substitute with a
known-good evaporator temperature sensor and check for proper operation. 6. If the problem is
corrected, replace the evaporator temperature sensor.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Specifications > Page 1158
REPLACEMENT
1. Pull out the passenger's crash pad center low cover (A). 2. Disconnect the connector pin (B).
3. Remove the evaporator temperature sensor (C) by pulling it after rotating 90 degrees in a
counterclockwise direction. 4. Installation is the reverse order of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component
Information > Locations
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DESCRIPTION
1. Humidity sensor is located at the lower crash pad and detects in-car humidity for in-car humidity
control.
2. If ambient air temperature or in-car humidity is outside certain range, it will turn on A/C to control
in-car humidity preventing in car fogging.
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INSPECTION
3. Check the frequency of humidity sensor between terminals 2 and 3. 4. If the measured
resistance is not specification, substitute with a known-good humidity sensor and check for proper
operation. 5. If the problem is corrected, replace the Humidity sensor.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component
Information > Locations > Page 1165
REPLACEMENT
1. Disconnect the negative (-) battery terminal. 2. Remove the lower crash panel (A). 3. Disconnect
humidity sensor connector.
4. Loosen the mounting screws (B) and then remove the humidity sensor (C). 5. Installation is the
reverse order of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations
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Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions
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Refrigerant Pressure Sensor / Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1171
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1174
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1175
l
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Symbols Part 1
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1176
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Symbols Part 2
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Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1177
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 1184
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Switch, HVAC > Component Information > Diagrams > Page 1186
Refrigerant Pressure Sensor / Switch: Description and Operation
DESCRIPTION
A/C pressure transducer convert the pressure value of high pressure line into voltage value after
measure it. By converted voltage value, engine ECU controls cooling fan by operating it high speed
or low speed. Engine ECU stop the operation of compressor when the temperature of refrigerant
line is so high or so low irregularly to optimize air conditioning system.
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Switch, HVAC > Component Information > Diagrams > Page 1187
INSPECTION
1. Measure the pressure of high pressure line by measuring voltage output between NO.1 and
NO.2 terminals. 2. Inspection the voltage value whether it is sufficient to be regular value or not.
3. If the measured voltage value is not specification, replace the A/C pressure transducer.
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Switch, HVAC > Component Information > Diagrams > Page 1188
REPLACEMENT
2. Disconnect A/C pressure transducer connector(A) (3P) from wiring harness. 3. Remove the A/C
pressure transducer.
Component Location
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Information > Locations > Component Locations > Page 1193
DESCRIPTION
1. The photo sensor is located at the right part of defrost nozzle. 2. The photo sensor contains a
photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light receiving portion,
generates an
electromotive force in proportion to the amount of radiation received which is transferred to the
automatic temperature control module so that the solar radiation compensation will be performed.
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Information > Locations > Page 1195
INSPECTION
1. Ignition "ON". 2. Using the scan tool. 3. Emit intensive light toward photo sensor using sunshine,
and check the output absolute voltage change.
4. The absolute voltage will rise with higher intensive light and reduce with lower intensive light.
NOTE: When checking photo sensor, select a place where is exposed to sunshine directly
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Information > Locations > Page 1196
REPLACEMENT
1. Disconnect the indirectly(-) battery terminal. 2. Using the (-) driver, Remove the photo sensor (B)
from the right part of defrost nozzle (A).
Remove the door switch and check for continuity between the terminals.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Locations
COMPONENTS m
Components
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions
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Fuel Gauge Sender: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1209
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1212
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1213
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1214
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1215
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1217
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Component Information > Diagrams > Diagram Information and Instructions > Page 1218
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1219
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1220
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1221
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1222
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 1223
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 1224
1. Using an ohmmeter, measure the resistance between terminals 1 and 3 of sender connector (A)
at each float level.
2. Also check that the resistance changes smoothly when the float is moved from "E" to "F" 3. If the
height resistance is unsatisfactory, replace the fuel sender as an assembly.
CAUTION: After completing this test, wipe the sender dry and reinstall it in the fuel tank.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch >
Component Information > Testing and Inspection
3. Check for continuity between the terminals in each position according to the table.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 06-97-001 > Apr > 06 >
Instruments - Incorrect Outside Temperature Displayed
Pa" ”3"“
Ambient Tmmmm
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LDDU Ambient 3: ms m3}
Sensor SHED-3 KUDU Ambient E AIDS (NF)
Number: 06-97-001
DESCRIPTION:
On some vehicles the ambient temperature displayed on the climate controller may differ from the
actual outside temperature by more than 5-10°F. An updated ambient temperature sensor is
available to improve this condition. This TSB provides the procedure to install the updated ambient
temperature sensor located in front of the radiator/condenser.
VEHICLES AFFECTED:
PARTS INFORMATION:
^ The current part number will continue to be used with the up ate part.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 06-97-001 > Apr > 06 >
Instruments - Incorrect Outside Temperature Displayed > Page 1236
Previnus New
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^ To determine if the vehicle has a factory installed or an updated part refer to the photos below.
REPLACEMENT PROCEDURE:
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5. Reset the A/C control head after ambient temperature sensor replacement.
^ Azera - Remove for 15 seconds the Power Connector Fuse (30 amp) from the passenger
compartment junction block and replace.
^ Sonata - Remove for 15 seconds the Power Connector 2 Fuse (15 amp) from the passenger
compartment junction block and replace.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > tnt1671006-02 >
Oct > 06 > A/C - Ambient Air Temperature Sensor Replacement
Outside Temperature Display Sensor: All Technical Service Bulletins A/C - Ambient Air
Temperature Sensor Replacement
DESCRIPTION:
On some vehicles the ambient temperature displayed on the climate controller may differ from the
actual outside temperature by more than 5-10°F. An updated ambient temperature sensor is
available to improve this condition. This article provides the procedure to install the updated
ambient temperature sensor located in front of the radiator/condenser.
VEHICLES AFFECTED:
PARTS INFORMATION
^ The current part number will continue to be used with the updated part.
^ To determine if the vehicle has a factory installed or an updated part, refer to the photos.
REPLACEMENT PROCEDURE:
bolt.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > tnt1671006-02 >
Oct > 06 > A/C - Ambient Air Temperature Sensor Replacement > Page 1243
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5. Reset the A/C control head after ambient temperature sensor replacement.
a. Azera - Remove for 15 seconds the Power Connector Fuse (30 amp) from the passenger
compartment junction block and replace.
b. Sonata - Remove for 15 seconds the Power Connector 2 Fuse (15 amp) from the passenger
compartment junction block and replace.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-97-001 > Apr
> 06 > Instruments - Incorrect Outside Temperature Displayed
Pa" ”3"“
Ambient Tmmmm
—9man-3 «
LDDU Ambient 3: ms m3}
Sensor SHED-3 KUDU Ambient E AIDS (NF)
Outside Temperature Display Sensor: All Technical Service Bulletins Instruments - Incorrect
Outside Temperature Displayed
Number: 06-97-001
DESCRIPTION:
On some vehicles the ambient temperature displayed on the climate controller may differ from the
actual outside temperature by more than 5-10°F. An updated ambient temperature sensor is
available to improve this condition. This TSB provides the procedure to install the updated ambient
temperature sensor located in front of the radiator/condenser.
VEHICLES AFFECTED:
PARTS INFORMATION:
^ The current part number will continue to be used with the up ate part.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-97-001 > Apr
> 06 > Instruments - Incorrect Outside Temperature Displayed > Page 1248
Previnus New
|Seria| Numbe
^ To determine if the vehicle has a factory installed or an updated part refer to the photos below.
REPLACEMENT PROCEDURE:
Inuirfliiih
97mm eaeaeamenuremhiant _
mm
Causal Fart
QTEBfl-flLfl-tm
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5. Reset the A/C control head after ambient temperature sensor replacement.
^ Azera - Remove for 15 seconds the Power Connector Fuse (30 amp) from the passenger
compartment junction block and replace.
^ Sonata - Remove for 15 seconds the Power Connector 2 Fuse (15 amp) from the passenger
compartment junction block and replace.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Outside
Temperature Display Sensor: > 09-EM-005 > Jul > 09 > Engine Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor/Switch: All Technical Service Bulletins Engine Controls - Oil Temperature
Sensor Oil Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
^ Torque Wrench
^ Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Outside
Temperature Display Sensor: > 09-EM-005 > Jul > 09 > Engine Controls - Oil Temperature Sensor Oil Leaks > Page 1261
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Testing and Inspection
INSPECTION
1. Remove the floor console and the connector (B) from the switch (A). 2. Inspect the continuity
between (-) terminal and the ground.
^ When the brake lever is pulled, there should be the continuity between them.
^ When the brake lever is released, there should be no continuity between them.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Locations
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Backup Lamp Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1271
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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> Component Information > Diagrams > Diagram Information and Instructions > Page 1274
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1275
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1276
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1277
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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> Component Information > Diagrams > Diagram Information and Instructions > Page 1279
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1280
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1281
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1282
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1283
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1284
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch
> Component Information > Diagrams > Diagram Information and Instructions > Page 1285
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls: > NHTSA09V280000 > Jul > 09 > Recall 09V280000:
Brake Light Switch Replacement
Brake Light Switch: Recalls Recall 09V280000: Brake Light Switch Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Hyundai/Accent 2005-2007 Hyundai/Azera
2005-2007 Hyundai/Elantra 2005-2007 Hyundai/Sonata 2005-2007 Hyundai/Tucson 2005-2007
MANUFACTURER: Hyundai Caribbean-Puerto Rico
SUMMARY: Hyundai is recalling 3,011 model year 2005-2007 Elantra, Tucson, Sonata, Azera and
Accent vehicles. A malfunctioning stop lamp switch may cause the brake lights to fail to illuminate
when the brake pedal is depressed or may cause the brake lights to remain illuminated when the
brake pedal is released. A defective stop lamp switch may also affect the operation of the
brake-transmission shift interlock feature so the transmission would not be able to be shift out of
the "PARK" position. It may also cause the Electronic Stability Control (ESC) malfunction light to
illuminate, and it may not deactivate the cruise control when the brake pedal is depressed.
REMEDY: Dealers will replace the stop lamp switch free of charge. The recall is expected to begin
during August 2009. Owners may contact Hyundai of Puerto Rico customer service at
787-999-4310.
NOTES: Hyundai of Puerto Rico recall No. 91B026. Owners may also contact The National
Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY
1-800-424-9153), or go to http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Recalls: > NHTSA09V122000 > Apr > 09 > Recall 09V122000:
Brake Lamp Switch Replacement
Brake Light Switch: Recalls Recall 09V122000: Brake Lamp Switch Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Hyundai/Accent 2006-2007 Hyundai/Azera 2007
Hyundai/Elantra 2007 Hyundai/Entourage 2006-2007 Hyundai/Santa Fe 2007 Hyundai/Sonata
2006-2007 Hyundai/Tucson 2005-2007 Hyundai/Veracruz 2007-2008 MANUFACTURER:
HYUNDAI MOTOR COMPANY
NHTSA ACTION NUMBER: PE09003 COMPONENT: Service Brakes, Hydraulic: Switches: Brake
Light
SUMMARY: Hyundai is recalling 531,894 M/Y 2006-2007 Accent, Entourage, Sonata, M/Y 2007
Azera, Elantra and Santa Fe, M/Y 2005-2007 Tucson and M/Y 2007-2008 Veracruz vehicles. The
stop lamp switch in the affected vehicles may malfunction. A malfunctioning stop lamp switch may
cause the brake lights to not illuminate when the brake pedal is depressed or may cause the brake
lights to remain illuminated when the brake pedal is released. A stop lamp switch malfunction may
affect the operation of the brake-transmission shift interlock feature so the transmission shifter
would not be able to be shifted out of park position. It may also cause the Electronic Stability
Control (ESC) malfunction light to illuminate, and it may not deactivate the cruise control when the
brake pedal is depressed.
REMEDY: Dealers will replace the stop lamp switch free of charge. The recall is expected to begin
during April 2009. Owners may contact Hyundai customer assistance center at 1-800-633-5151.
NOTES: Hyundai recall No. 092. Owners may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Customer Interest: > 08-BE-005 > Jul > 08 > Lighting - Brake
Lamps Inoperative/DTC's P0504/C1513
l. alums-mm
layman-mm
El. 'El-Jl'fllmHl-fir
lEfl-nFn-flfinfl
:'-. m m m w m m I:-
Brake Light Switch: Customer Interest Lighting - Brake Lamps Inoperative/DTC's P0504/C1513
Group: BODY ELECTRICAL
Number: 08-BE-005
DESCRIPTION:
This TSB describes the procedure to adjust the stop lamp switch. In most cases, proper adjustment
of the stop lamp switch will resolve DTC's P0504 (brake switch) and C1513 (brake light switch)
without replacing the stop lamp switch.
If the vehicle exhibits inoperative brake lights or DTC codes P0504 or C1513 use the following
procedure to ensure proper diagnosis.
NOTE:
Two stop lamp switches have been installed on 2006 Sonatas. The switches are interchangeable.
NOTE:
Vehicles with a VIN starting with 5NPEU produced before 8/19/05 have a metal housing (left),
vehicles produced on or after 8/19/05 have a plastic housing (right).
NOTE:
Vehicles with a VIN starting with KMHET produced before 4/28/05 have a metal housing (left),
vehicles produced on or after 4/28/05 have a plastic housing (right).
COMPONENTS:
SERVICE PROCEDURE:
1. Check the clearance between the stop lamp switch housing and the brake pedal when the pedal
is in the free position.
2. If the clearance is within specification and the stop lamp switch continues to not function
properly, check the operation of the switch.
3. Remove the stop lamp switch by loosening the brake switch lock nuts. Depress the stop lamp
switch plunger manually and see if the brake lights function properly.
4. If the stop lamp switch does not function properly, check the continuity of the stop lamp switch.
6. Check the continuity of the stop lamp switch by connecting the multimeter to the upper contacts.
7. With the plunger not depressed, the meter should read approximately 0 ohms, has continuity.
8. Depress the stop lamp switch plunger. Multimeter should read open circuit (no continuity).
9. Connect the multimeter connectors to the lower contacts on the stop lamp switch.
10. With the plunger not depressed, the meter should read open circuit (no continuity).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > Customer Interest: > 08-BE-005 > Jul > 08 > Lighting - Brake
Lamps Inoperative/DTC's P0504/C1513 > Page 1304
11. Depress the stop lamp switch plunger. Multimeter should read approximately 0 ohms, has
continuity.
12. If the stop lamp switch does not pass the continuity test, replace the stop lamp switch.
13. If the stop lamp switch does pass the continuity test, recheck the brake pedal stopper to stop
lamp switch clearance or follow the shop manual ETM to diagnose wiring.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA09V280000 > Jul > 09 >
Recall 09V280000: Brake Light Switch Replacement
Brake Light Switch: All Technical Service Bulletins Recall 09V280000: Brake Light Switch
Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Hyundai/Accent 2005-2007 Hyundai/Azera
2005-2007 Hyundai/Elantra 2005-2007 Hyundai/Sonata 2005-2007 Hyundai/Tucson 2005-2007
MANUFACTURER: Hyundai Caribbean-Puerto Rico
SUMMARY: Hyundai is recalling 3,011 model year 2005-2007 Elantra, Tucson, Sonata, Azera and
Accent vehicles. A malfunctioning stop lamp switch may cause the brake lights to fail to illuminate
when the brake pedal is depressed or may cause the brake lights to remain illuminated when the
brake pedal is released. A defective stop lamp switch may also affect the operation of the
brake-transmission shift interlock feature so the transmission would not be able to be shift out of
the "PARK" position. It may also cause the Electronic Stability Control (ESC) malfunction light to
illuminate, and it may not deactivate the cruise control when the brake pedal is depressed.
REMEDY: Dealers will replace the stop lamp switch free of charge. The recall is expected to begin
during August 2009. Owners may contact Hyundai of Puerto Rico customer service at
787-999-4310.
NOTES: Hyundai of Puerto Rico recall No. 91B026. Owners may also contact The National
Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY
1-800-424-9153), or go to http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA09V122000 > Apr > 09 >
Recall 09V122000: Brake Lamp Switch Replacement
Brake Light Switch: All Technical Service Bulletins Recall 09V122000: Brake Lamp Switch
Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Hyundai/Accent 2006-2007 Hyundai/Azera 2007
Hyundai/Elantra 2007 Hyundai/Entourage 2006-2007 Hyundai/Santa Fe 2007 Hyundai/Sonata
2006-2007 Hyundai/Tucson 2005-2007 Hyundai/Veracruz 2007-2008 MANUFACTURER:
HYUNDAI MOTOR COMPANY
NHTSA ACTION NUMBER: PE09003 COMPONENT: Service Brakes, Hydraulic: Switches: Brake
Light
SUMMARY: Hyundai is recalling 531,894 M/Y 2006-2007 Accent, Entourage, Sonata, M/Y 2007
Azera, Elantra and Santa Fe, M/Y 2005-2007 Tucson and M/Y 2007-2008 Veracruz vehicles. The
stop lamp switch in the affected vehicles may malfunction. A malfunctioning stop lamp switch may
cause the brake lights to not illuminate when the brake pedal is depressed or may cause the brake
lights to remain illuminated when the brake pedal is released. A stop lamp switch malfunction may
affect the operation of the brake-transmission shift interlock feature so the transmission shifter
would not be able to be shifted out of park position. It may also cause the Electronic Stability
Control (ESC) malfunction light to illuminate, and it may not deactivate the cruise control when the
brake pedal is depressed.
REMEDY: Dealers will replace the stop lamp switch free of charge. The recall is expected to begin
during April 2009. Owners may contact Hyundai customer assistance center at 1-800-633-5151.
NOTES: Hyundai recall No. 092. Owners may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-BE-005 > Jul > 08 > Lighting -
Brake Lamps Inoperative/DTC's P0504/C1513
l. alums-mm
layman-mm
El. 'El-Jl'fllmHl-fir
lEfl-nFn-flfinfl
:'-. m m m w m m I:-
Brake Light Switch: All Technical Service Bulletins Lighting - Brake Lamps Inoperative/DTC's
P0504/C1513
Number: 08-BE-005
DESCRIPTION:
This TSB describes the procedure to adjust the stop lamp switch. In most cases, proper adjustment
of the stop lamp switch will resolve DTC's P0504 (brake switch) and C1513 (brake light switch)
without replacing the stop lamp switch.
If the vehicle exhibits inoperative brake lights or DTC codes P0504 or C1513 use the following
procedure to ensure proper diagnosis.
NOTE:
Two stop lamp switches have been installed on 2006 Sonatas. The switches are interchangeable.
NOTE:
Vehicles with a VIN starting with 5NPEU produced before 8/19/05 have a metal housing (left),
vehicles produced on or after 8/19/05 have a plastic housing (right).
NOTE:
Vehicles with a VIN starting with KMHET produced before 4/28/05 have a metal housing (left),
vehicles produced on or after 4/28/05 have a plastic housing (right).
COMPONENTS:
SERVICE PROCEDURE:
1. Check the clearance between the stop lamp switch housing and the brake pedal when the pedal
is in the free position.
2. If the clearance is within specification and the stop lamp switch continues to not function
properly, check the operation of the switch.
3. Remove the stop lamp switch by loosening the brake switch lock nuts. Depress the stop lamp
switch plunger manually and see if the brake lights function properly.
4. If the stop lamp switch does not function properly, check the continuity of the stop lamp switch.
6. Check the continuity of the stop lamp switch by connecting the multimeter to the upper contacts.
7. With the plunger not depressed, the meter should read approximately 0 ohms, has continuity.
8. Depress the stop lamp switch plunger. Multimeter should read open circuit (no continuity).
9. Connect the multimeter connectors to the lower contacts on the stop lamp switch.
10. With the plunger not depressed, the meter should read open circuit (no continuity).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-BE-005 > Jul > 08 > Lighting -
Brake Lamps Inoperative/DTC's P0504/C1513 > Page 1319
11. Depress the stop lamp switch plunger. Multimeter should read approximately 0 ohms, has
continuity.
12. If the stop lamp switch does not pass the continuity test, replace the stop lamp switch.
13. If the stop lamp switch does pass the continuity test, recheck the brake pedal stopper to stop
lamp switch clearance or follow the shop manual ETM to diagnose wiring.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > tnt1630506-02 > May > 06 >
Lighting - Brake Light Switch Adjustment Procedure
Brake Light Switch: All Technical Service Bulletins Lighting - Brake Light Switch Adjustment
Procedure
DESCRIPTION:
This article describes the procedure to adjust the stop lamp switch. In most cases, proper
adjustment of the stop lamp switch will resolve DTC's P0504 (brake switch) and C1513 (brake light
switch) without unnecessary replacement of the stop lamp switch.
If the vehicle exhibits inoperative brake lights or DTC codes P0504 or C1513, use the following
procedure to ensure proper diagnosis.
NOTE:
Two stop lamp switches have been installed on 2006 Sonatas. The switches are interchangeable.
NOTE:
Vehicles with a VIN starting with 5NPEU produced before 8/19/05 have a metal housing (left);
vehicles produced after 8/19/05 have a plastic housing (right).
NOTE:
Vehicles with a VIN starting with KMHET produced before 4/28/05 have a metal housing (left);
vehicles produced after 4/28/05 have a plastic housing (right).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > tnt1630506-02 > May > 06 >
Lighting - Brake Light Switch Adjustment Procedure > Page 1324
COMPONENTS:
1. Stop Lamp Switch Assembly
SERVICE PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > tnt1630506-02 > May > 06 >
Lighting - Brake Light Switch Adjustment Procedure > Page 1325
1. Check the clearance between the stop lamp switch housing and the brake pedal when the pedal
is in the free position.
Specification: A-B = 0.5 - 1.0 mm (0.02~0.04 in) A - Stop Lamp Switch Metal Housing B - Brake
Pedal Stopper
2. If the clearance is within specification and the stop lamp switch continues to not function
properly, check the operation of the switch.
3. Remove the stop lamp switch by loosening the brake switch lock nuts. Depress the stop lamp
switch plunger manually and see if the brake lights
function properly.
4. If the stop lamp switch does not function properly, check the continuity of the stop lamp switch.
8. Depress the stop lamp switch plunger. Multi meter should read open circuit (no continuity}).
9. Connect the multimeter connectors to the lower contacts on the stop lamp switch.
10. With the plunger not depressed, the meter should read open circuit (no continuity).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > tnt1630506-02 > May > 06 >
Lighting - Brake Light Switch Adjustment Procedure > Page 1328
11. Depress the stop lamp switch plunger. Multi meter should read approximately 0 ohms, has
continuity.
12. If the stop lamp switch does not pass the continuity test, replace the stop lamp switch.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > tnt1630506-02 > May > 06 >
Lighting - Brake Light Switch Adjustment Procedure > Page 1329
13. If the stop lamp switch does pass the continuity test, recheck the brake pedal stopper to stop
lamp switch clearance or follow the shop manual FTM to diagnose wiring.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK'
Shift Interlock Control Module: All Technical Service Bulletins A/T - Can't Shift Into/Out Of 'PARK'
Number: 06-40-008-1
Subject: AUTOMATIC TRANSAXLE SHIFT LEVER WILL NOT SHIFT OUT OF PARK
DESCRIPTION:
If the shift lever of a 2006 Sonata, Azera or 2007 Santa Fe, Elantra or Entourage vehicle does not
shift into or out of Park, please follow the repair procedure:
REPAIR PROCEDURE:
^ Vehicle
^ "Automatic Transaxle",
^ "Current Data"
^ Brake Switch"
2. Confirm the "Brake Switch" reads "ON" when the brake pedal is depressed. If not, check the
brake switch clearance according to the related shop manual. If the clearance is within
specification, install a known-good brake switch:
^ Check fuses and related wiring as shown in the related E/M, page 5D452-2.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1335
Remove
nuts
HIM H'HLEVII
Emir." _
-'IT'H P - E ' I ‘ L C C K
- ':- mmmr
2006 - SONATA
^ Refer to the 2006 or 2007 Sonata Shop Manual, page BD-52 and remove the center panel.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
2006 - AZERA:
^ Refer to the 2006 or 2007 Azera Shop Manual, page BD-62 and remove the glove box.
^ Remove the two nuts and disconnect the M76 connector to the ATM key lock control module. Go
to "Test Procedure".
2007 - ENTOURAGE:
^ Refer to the 2007 Entourage Shop Manual, page BD-61 and remove the floor console cover.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1336
2007 - SANTA FE:
^ Refer to the 2007 Santa Fe Shop Manual, page BD-63 and remove the center fascia panel.
^ Disconnect the M02 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Santa Fe ETM, page CL- 11, photo 61 for clarity).
2007 - ELANTRA
^ Refer to the 2007 Elantra Shop Manual, page BD-51 and remove the lower panel.
^ Disconnect the M12 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Elantra ETM, page CL-7, photo 38 for clarity).
TEST PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1337
EflflTH ELANTRA
Ftaplau-a ATM
n- 9535!]-
Qfiflfifl-
EI-lflflfl
“NEH
W34: Innparafiva
"U15; PIEHJI' ml'llflEf-l E: Eil'flLfl'L flpfll'l Eir'Guil
3. Turn the ignition switch to the "ON" position. Check voltage at the pins according to table. If the
voltages are correct, replace the ATM key lock control module.
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1343
Remove
nuts
HIM H'HLEVII
Emir." _
-'IT'H P - E ' I ‘ L C C K
- ':- mmmr
2006 - SONATA
^ Refer to the 2006 or 2007 Sonata Shop Manual, page BD-52 and remove the center panel.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
2006 - AZERA:
^ Refer to the 2006 or 2007 Azera Shop Manual, page BD-62 and remove the glove box.
^ Remove the two nuts and disconnect the M76 connector to the ATM key lock control module. Go
to "Test Procedure".
2007 - ENTOURAGE:
^ Refer to the 2007 Entourage Shop Manual, page BD-61 and remove the floor console cover.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1344
2007 - SANTA FE:
^ Refer to the 2007 Santa Fe Shop Manual, page BD-63 and remove the center fascia panel.
^ Disconnect the M02 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Santa Fe ETM, page CL- 11, photo 61 for clarity).
2007 - ELANTRA
^ Refer to the 2007 Elantra Shop Manual, page BD-51 and remove the lower panel.
^ Disconnect the M12 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Elantra ETM, page CL-7, photo 38 for clarity).
TEST PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1345
EflflTH ELANTRA
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3. Turn the ignition switch to the "ON" position. Check voltage at the pins according to table. If the
voltages are correct, replace the ATM key lock control module.
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1351
Remove
nuts
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2006 - SONATA
^ Refer to the 2006 or 2007 Sonata Shop Manual, page BD-52 and remove the center panel.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
2006 - AZERA:
^ Refer to the 2006 or 2007 Azera Shop Manual, page BD-62 and remove the glove box.
^ Remove the two nuts and disconnect the M76 connector to the ATM key lock control module. Go
to "Test Procedure".
2007 - ENTOURAGE:
^ Refer to the 2007 Entourage Shop Manual, page BD-61 and remove the floor console cover.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1352
2007 - SANTA FE:
^ Refer to the 2007 Santa Fe Shop Manual, page BD-63 and remove the center fascia panel.
^ Disconnect the M02 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Santa Fe ETM, page CL- 11, photo 61 for clarity).
2007 - ELANTRA
^ Refer to the 2007 Elantra Shop Manual, page BD-51 and remove the lower panel.
^ Disconnect the M12 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Elantra ETM, page CL-7, photo 38 for clarity).
TEST PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Light Switch: > 06-40-008-1 >
Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 1353
EflflTH ELANTRA
Ftaplau-a ATM
n- 9535!]-
Qfiflfifl-
EI-lflflfl
“NEH
W34: Innparafiva
"U15; PIEHJI' ml'llflEf-l E: Eil'flLfl'L flpfll'l Eir'Guil
3. Turn the ignition switch to the "ON" position. Check voltage at the pins according to table. If the
voltages are correct, replace the ATM key lock control module.
PARTS INFORMATION
WARRANTY INFORMATION
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Component Information > Technical Service Bulletins > Page 1354
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions
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Brake Light Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1357
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Component Information > Diagrams > Diagram Information and Instructions > Page 1360
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1361
l
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Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1362
fi
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1363
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1365
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Component Information > Diagrams > Diagram Information and Instructions > Page 1366
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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Component Information > Diagrams > Diagram Information and Instructions > Page 1367
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1368
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Component Information > Diagrams > Diagram Information and Instructions > Page 1369
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Component Information > Diagrams > Diagram Information and Instructions > Page 1370
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1371
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Page 1372
BRAKE PEDAL
INSPECTION
1. Check the bushing for wear. 2. Check the brake pedal for bending or twisting. 3. Check the
brake pedal return spring for damage.
1) Connect a circuit tester to the connector of stop lamp switch, and check whether or not there is
continuity when the plunger of the stop lamp
2) The stop lamp switch is in good condition if there is no continuity when plunger (A) is pushed.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Specifications
SPECIFICATIDHS mus
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Linhllun ltuh m m : 1* {M had}
'liJrn algal E Ian: manna alum fifltflfifl {Law load}
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Lair. Hlm : 4.5a {Mater load]
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Specifications > Page 1377
CUMPDNENTS arm
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Components
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Component Information > Specifications > Page 1378
INSPECTION
With the multi function switch in each position, make sure that continuity exists between the
terminals. If continuity is not as specified, replace the multi-function switch.
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With the multi function switch in each position, make sure that continuity exists between the
terminals. If continuity is not as specified, replace the multi-function switch.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Specifications > Page 1381
Combination Switch: Service and Repair
REPLACEMENT
2. Remove the steering column upper and lower shrouds (A) after removing 3 screws.
3. Remove the light switch (A) by pushing the lock pin (B) after disconnecting the connector.
4. Remove the wiper switch (A) by pushing the lock pin (B) after disconnecting the connector. 5.
Installation is the reverse of removal.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Front Door Switch
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Component Information > Locations > Front Door Switch > Page 1386
Remove the door switch and check for continuity between the terminals.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp
Switch > Component Information > Locations
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Switch > Component Information > Locations
RHEOSTAT
INSPECTION
2. Remove the lower crash pad switch (A) from the side crash pad cover (B) by using the scraper
(C) and then disconnect the connectors.
4. Check for intensity. If the light intensity of the lamps changes smoothly without any flickering
when the rheostat is turned, it can be assumed that
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Headlamp Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Component Information > Diagrams > Diagram Information and Instructions > Page 1401
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1404
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1405
l
l
P
I
n.
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35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1406
fi
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1407
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1409
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1410
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1411
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1412
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Component Information > Diagrams > Diagram Information and Instructions > Page 1414
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor: > 10-EE-002 > Jul > 10 > Engine Controls -
MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor: > 07-36-006 > Sep > 07 > Engine Controls -
Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - Low Power/MIL ON/DTC
P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
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Example GDS DTC screen shown.
DP CASUAL CUBE
firljflDEL 01’ NAME TIME PART I
NATURE CAUSE
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3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Accelerator Pedal Position Sensor: > 10-EE-002 > Jul > 10 > Engine
Controls - MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Accelerator Pedal Position Sensor: > 07-36-006 > Sep > 07 > Engine
Controls - Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - Low
Power/MIL ON/DTC P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
j
a Frau“ Frlma j
m m m m m : m u
l m h | II'h'lTl-fl
Human—um cum -
n nun-1mm I.- I
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Example GDS DTC screen shown.
DP CASUAL CUBE
firljflDEL 01’ NAME TIME PART I
NATURE CAUSE
327m 3mm
msmnw DIAGHDEIE
3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 1450
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 1452
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 1453
No.53
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 1454
DEECRIPTIDH emu:
Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 1455
DESCRIPTIDN mm
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SPECIFIEATIDH
Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 1456
SCHEHATIE DMHAH
[macurr DMEHMJ]
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Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page
1461
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page
1462
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1465
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Information and Instructions > Page 1469
35
3
Symbols Part 1
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Information and Instructions > Page 1470
.—
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Symbols Part 2
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Information and Instructions > Page 1471
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
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SPECIFICATION
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Air Flow Meter/Sensor: Testing and Inspection
DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
Specification
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SGHEHATI‘E m m
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Schematic Diagram
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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murmur wuss M
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations >
Component Locations
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Camshaft Position Sensor: Component Locations
Bank 1
Bank 2
'-
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Component Locations > Page 1488
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Overview
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Component Locations > Page 1489
PHOTO.35
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Information and Instructions > Page 1495
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Information and Instructions > Page 1496
35
3
Symbols Part 1
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Information and Instructions > Page 1497
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Information and Instructions > Page 1498
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Information and Instructions > Page 1501
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Information and Instructions > Page 1503
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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1507
DESCRIPTION Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft
position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects
the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which out- put voltage changes when magnetic field is made on the IC with
current flow. So the sequential injection of the 6 cylinders is impossible without CMPS signal.
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DESCRIPTION Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft
position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects
the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which out- put voltage changes when magnetic field is made on the IC with
current flow. So the sequential injection of the 6 cylinders is impossible without CMPS signal.
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1509
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1513
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1514
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Information > Specifications > Page 1515
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
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DESCRIPTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
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Information > Specifications > Page 1517
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Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
Specification
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
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Page 1522
Detail
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Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
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Symbols Part 1
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1539
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
1540
DESCRIPTION Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of
the most important sensors of the engine control system. If there is no CKPS signal input, fuel is
not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal.
This sensor is installed on transaxle housing and generates alternating current by magnetic flux
field which is made by the sensor and the target wheel when engine runs. The magnetic flux
increases when the protrusion of the target wheel is getting near to the sensor and does not
change in the most close position. When the protrusion becomes estranged from the sensor,
magnetic flux disappears and alternating current is generated. The target wheel consists of 58 slots
and 2 missing slots on 360 CA (Crank Angle).
.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
1541
é.
3
WAVEFO'RH
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rl-IfI-l-I
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DESCRIPTION Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of
the most important sensors of the engine control system. If there is no CKPS signal input, fuel is
not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal.
This sensor is installed on transaxle housing and generates alternating current by magnetic flux
field which is made by the sensor and the target wheel when engine runs. The magnetic flux
increases when the protrusion of the target wheel is getting near to the sensor and does not
change in the most close position. When the protrusion becomes estranged from the sensor,
magnetic flux disappears and alternating current is generated. The target wheel consists of 58 slots
and 2 missing slots on 360 CA (Crank Angle).
Waveform
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
1542
ECEEHATIG DIAGRAM
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
COMPONENTS m
Components
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications >
Page 1550
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications >
Page 1551
:
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications >
Page 1552
DESCRIPTION enema
Description
The evaporative emission control system prevents hydrocarbon vapors from escaping from the fuel
tank into the atmosphere where they could form photochemical smog. Gasoline vapors are
collected in the charcoal canister. The Fuel Tank Pressure Sensor (FTPS) is installed on fuel pump
assembly and is an integral part of the evaporative monitoring system. The PCM monitors the
FTPS signal to detect vacuum decay and excess vacuum. The FTPS measures the difference
between the air pressure inside the fuel tank and outside air pressure to check the purge control
solenoid valve operation and for leak detection in the evaporative emission control system by
monitoring pressure and vacuum levels in the fuel tank during the purge control solenoid valve
operating cycles.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications >
Page 1553
DESCRIPTION enema
SPEEIFICATIDH
Description
The evaporative emission control system prevents hydrocarbon vapors from escaping from the fuel
tank into the atmosphere where they could form photochemical smog. Gasoline vapors are
collected in the charcoal canister. The Fuel Tank Pressure Sensor (FTPS) is installed on fuel pump
assembly and is an integral part of the evaporative monitoring system. The PCM monitors the
FTPS signal to detect vacuum decay and excess vacuum. The FTPS measures the difference
between the air pressure inside the fuel tank and outside air pressure to check the purge control
solenoid valve operation and for leak detection in the evaporative emission control system by
monitoring pressure and vacuum levels in the fuel tank during the purge control solenoid valve
operating cycles.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Specifications >
Page 1554
SBHEHATIG MEAN!
l
[GIHGUI'I' DIAE'IFMM] [WHNEGTIUH IHF'DFIMATIUH]
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications >
Page 1559
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications >
Page 1560
DESCRIPTION EWEEGBJ:
'.l .I_.
._l
w 15* ‘ fl fi - i fl fi fl fl fl fi l fl fi fl ' fl ‘ l fl fi
L.________W i
Efiqrflfi-fi-‘u
Description
DESCRIPTION Intake Air Temperature Sensor (IATS) is installed inside the Mass Air Flow Sensor
(MAFS) and detects the intake air temperature. To calculate precise air quantity, correction of the
air temperature is needed because air density varies according to the temperature. So the PCM
uses not only MAFS signal but also IATS signal. This sensor has a Negative Temperature
Coefficient (NTC) and its resistance is in inverse proportion to the temperature.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications >
Page 1561
DESCRIPTION EWEEGBJ:
.1" ..afif’ fl fi - i fl E M E E E M E 1 1 fl i fl l fi - L
L_______“'"""‘"‘“’ E'E'JII'EEEl-‘u
SPECIFICATION
Description
DESCRIPTION Intake Air Temperature Sensor (IATS) is installed inside the Mass Air Flow Sensor
(MAFS) and detects the intake air temperature. To calculate precise air quantity, correction of the
air temperature is needed because air density varies according to the temperature. So the PCM
uses not only MAFS signal but also IATS signal. This sensor has a Negative Temperature
Coefficient (NTC) and its resistance is in inverse proportion to the temperature.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications >
Page 1562
SCHEMATIG 0mm
EBHFEE‘A
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations
‘ _ _ — -
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations
> Page 1567
311T
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Component Locations
> Page 1568
PHDTIJ.”
3.3L - '
' ' mum-arm I.
r'I'HHEIT'IIE HEMDH
Inna—1 mac:
5EH51'JFI l1 .
mm mm mum A I
TEHPEHJI TLH'E IEHIDII.
in semen
5 * -
min: -: HIHEIEIE
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SPEC IFEATI-DH
Specification
DESCRIPTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine
damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the
V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is
applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the
knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing.
This sequential control can improve engine power, torque and fuel economy.
Item.......................................................................................................................................................
..............................................................Specification
Capacitance..........................................................................................................................................
..........................................................1,480 - 2,220 pF
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1570
EPEL' IFEATI-DH
EPEBIFIEA'I'IDH
Specification
DESCRIPTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine
damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the
V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is
applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the
knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing.
This sequential control can improve engine power, torque and fuel economy.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1571
EEHEHATIG MAE-RAH
" E —
“ m —
EDRFEE-I-I-fl.
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
HFEF'IEHE
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 1576
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 1577
PHOTD.35
'SJL; i“ .r
_ £715....
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DESCRIPTION Elm
Description
DESCRIPTION
Manifold Absolute Pressure Sensor (MAPS) is speed-density type sensor and is installed on the
surge tank. This MAPS senses absolute pressure in surge tank and transfers this analog signal
proportional to the pressure to the PCM. The PCM calculates the intake air quantity and engine
speed based on this signal. This MAPS consists of piezo-electric element and hybrid IC that
amplifies the element output signal. The element is silicon diaphragm type and adapts pressure
sensitive variable resistor effect of semi-conductor 100% vacuum and the manifold pressure
applies to both sides of it respectively. That is, this sensor outputs the silicon variation proportional
to pressure change by voltage.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 1579
DESCRIPTION Elm
SPECIFICATION
Description
DESCRIPTION
Manifold Absolute Pressure Sensor (MAPS) is speed-density type sensor and is installed on the
surge tank. This MAPS senses absolute pressure in surge tank and transfers this analog signal
proportional to the pressure to the PCM. The PCM calculates the intake air quantity and engine
speed based on this signal. This MAPS consists of piezo-electric element and hybrid IC that
amplifies the element output signal. The element is silicon diaphragm type and adapts pressure
sensitive variable resistor effect of semi-conductor 100% vacuum and the manifold pressure
applies to both sides of it respectively. That is, this sensor outputs the silicon variation proportional
to pressure change by voltage.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 1580
SEHEIIATIG DIAGRAM
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Customer Interest for Oil Temperature Sensor For ECM: > 09-EM-005 > Jul > 09 > Engine Controls - Oil
Temperature Sensor Oil Leaks
Oil Temperature Sensor For ECM: Customer Interest Engine Controls - Oil Temperature Sensor Oil
Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Oil Temperature Sensor For ECM: > 09-EM-005 > Jul > 09 > Engine
Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor For ECM: All Technical Service Bulletins Engine Controls - Oil
Temperature Sensor Oil Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 1596
HI'EFIEHD
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 1598
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 1599
SPEEIFIGATDH
Oil Temperature Sensor For ECM: Description and Operation
DESCRIPTION
Continuously Variable Valve Timing (CVVT) system controls valve overlap by forcibly activating the
camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas (NOx,
HC) and improves fuel economy, idle state, torque in low speed and power in high speed. This
system uses engine oil pressure and consists of the two CVVT Oil Control Valves (OCV) in each
bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 1600
SCHEIIA'I'IG DIAGRAH
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 1601
SPEEIFIGATDH
Oil Temperature Sensor For ECM: Testing and Inspection
DESCRIPTION
Continuously Variable Valve Timing (CVVT) system controls valve overlap by forcibly activating the
camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas (NOx,
HC) and improves fuel economy, idle state, torque in low speed and power in high speed. This
system uses engine oil pressure and consists of the two CVVT Oil Control Valves (OCV) in each
bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 1602
SCHEIIA'I'IG DIAGRAH
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine Controls - DTC P0300-P0306 Diagnostics
Oxygen Sensor: Technical Service Bulletins Engine Controls - DTC P0300-P0306 Diagnostics
P0300-P0306 AND/OR FRONT OXYGEN SENSOR DTC
DESCRIPTION:
This bulletin provides diagnostic procedures for 2006- 2007 vehicles with 3.3L3.8L engines and the
following DTC stored: P0300-P0306 engine misfire DTC and Freeze Frame Data Fuel Trim of at
least - 20% indicating rich shift. or any of the following 02 sensor DTC: ^
NOTE:
The vehicle may also exhibit an intermittent hesitation when the engine is at operating temperature.
SERVICE PROCEDURE:
1. DTC P0300-P0306 Misfire but no O2 sensor DTC stored: Inspect the Freeze Frame Data for
either the Long Term or Short Term Fuel Trim shifted -20% or more at a particular bank. The
following example illustrates the fuel trim of -20% or more occurred at Bank-i only:
3. Should either #1 or #2 condition be present replace the related Front O2 sensor at the applicable
bank:
NOTE:
: D-TE
' Elsi: Impficflnn
DTl: Anilysi: — * d E — — ‘ - - L - h *
'El Fl'llfl'FTl'l'l
mmlll‘l'fl'l'rmm?“
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PARTS INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine Controls - DTC P0300-P0306 Diagnostics > Page 1609
Bank-2 LH {U P} Sensor.
m arm will! lil'TllE m m
”I “ I I I Bill
Number 10-FL-012
Model 3.3L SANTA FE AND SONATA, 3.8L ENTOURAGE, AZERA, AND VERACRUZ
This bulletin supersedes TSB# 08-FL-002-1 to correct model year and OP Code time.
DESCRIPTION:
This bulletin provides diagnostic procedures for 2006-2009 vehicles with 3.3L/3.8L engines and the
following DTC stored:
P0300-P0306 engine misfire DTC and Freeze Frame Data Fuel Trim of at least - 20% indicating
rich shift.
APPLICABLE VEHICLES: ^ 2006-2009 3.3L Santa Fe and Sonata ^ 2006-2009 3.8L Entourage,
Azera, and Veracruz
SERVICE PROCEDURE:
Inspect the Freeze Frame Data for either the Long Term or Short Term Fuel Trim shifted -20% or
more at a particular bank. The following example illustrates the fuel trim of -20% or more occurred
at Bank-1 only:
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine Controls - DTC P0300-P0306 Diagnostics > Page 1611
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2. Inspect for any of the following Front 02 sensor DTC(s) stored:
NOTE:
The following Rear 02 sensor DTC may have set as a result of the Front 02 sensor:
PARTS IHFDRHATIDN:
PARTS INFORMATION
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Engine Controls - DTC P0300-P0306 Diagnostics > Page 1613
TIME PIN
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WARRANTY INFORMATION
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Page 1614
Bank 1 / Sensor 2
Bank 2 / Sensor 1
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 1617
Bank 2 / Sensor 2
'-
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 1618
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 1619
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and Instructions > Page 1623
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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and Instructions > Page 1626
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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and Instructions > Page 1627
35
3
Symbols Part 1
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and Instructions > Page 1628
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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and Instructions > Page 1629
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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DESCRIPTION
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream
and downstream of the Manifold Catalyst Converter (MCC). After it compares oxygen consistency
of the atmosphere with the exhaust gas, it transfers the oxygen consistency of the exhaust gas to
the PCM. When A/F ratio is rich or lean, it generates approximately 1 V or 0 V respectively. In order
that this sensor normally operates, the temperature of the sensor tip is higher than 370 degrees C
(698 degrees F). So it has a heater which is controlled by the PCM duty signal. When the exhaust
gas temperature is lower than the specified value, the heater warms the sensor tip.
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Oxygen Sensor: Testing and Inspection
DESCRIPTION
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream
and downstream of the Manifold Catalyst Converter (MCC). After it compares oxygen consistency
of the atmosphere with the exhaust gas, it transfers the oxygen consistency of the exhaust gas to
the PCM. When A/F ratio is rich or lean, it generates approximately 1 V or 0 V respectively. In order
that this sensor normally operates, the temperature of the sensor tip is higher than 370 degrees C
(698 degrees F). So it has a heater which is controlled by the PCM duty signal. When the exhaust
gas temperature is lower than the specified value, the heater warms the sensor tip.
Specification
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Schematic Diagram
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Detail
'-
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Page 1644
311T
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Overview
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations >
Page 1645
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2135/P0638
Group: FUEL SYSTEM
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1654
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Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
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Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1655
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nrrnsrszesmm
3333M? unflwsmmm
HHH33-33333H333
33113- "31333333313133
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"Hm—333333333
HFflH—STEEAEBJHM
HFflHBTEiASfl-IAM
33113- "Famrsmsmnm
23mm 33333 HFflflaa‘SEASflJADA Hflflmm
HFBH33*$2A5«BJFBA
HFEHETSEAEBJHEA
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HFEH33'52AEBJHBA "Film-333333333
it...
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tile}.r teaching
3"" "I”
“a”writing
With
{EU-BTW) 391flfi-
3mm . n
EHEHfl-B hi2 THE“ EHrrietr-Mr'timh, pmmdumfi
required
EH?"3-‘B*M2"BJHA‘
EH7"33*M2“BJHB" -
EN?“3£*ME“BJHD‘
mm“ 351”6'
t“
EHEH33*52"TF4G‘
EHENJB*32"?F4E* EHTHI-B‘BP'EJHA'
m-
“WNW
mun"
{warm 30450
Emnaetszttemilr
EHi'Hae-ezt-eJHe' -
EHi'Hee-sr—EJHD'
EN?N33*M2**TG33*
ENTN3fl*M2**TG:iG*
Emuae-ME-wnh' menarnrrmnt
With entue— EWHSB‘ME“?J1A*
{2003mm 3cm ENEN38*M2**8JVA*
Ehieneathtz-temr
EHBHEE‘MT‘BJHC‘ Enumermr-WWN
EHEHSB'ME'*BJHJ*
Eitmeiitezttreae-
mm“
[tiehm 391“5'
3mm
M M mwm
EHrHee-ez-tntm
emnea-srtemm on“,
EHBM33*32"BJHG* ENBHH‘EP'W“
EHENJB*$2**BJHJ*
EHThiee-Mzt-rJtet
Ettrhiaeriuizttntet EHBNEE'MF'BJIB‘
With 391flfi- fiflflfl‘MFWF
{EWEWJ 36412 ENEMEE*M2“BJHB‘
EHBNBB‘MT‘BJHD‘ enemas-ureter?
EHBH33*M2"BJHH'
Hummer-rue" Emmyflflum
Withuut etime- Ettmaetezttnzet
ten-new) 3G4— EHBtiaB. $2__BJHE‘
EHEH33*52“EJHD* ENEMEE”52“HJWB‘
Etienne-ertiunitt
NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1661
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1662
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1663
Tm: I: pun-gran for updltlng EDI.
Darn llll‘llfll a m [In-gm. durum flu upflh.
I] I 3
5%
ROM ID Reading...
4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1664
I«'Iehuirflle 51W Management
m J || .‘U-r'lll' r.41.':‘-1:'II'IT.'-; 3 ."ir'II'IIHI". ;. Fr.;.r.-...-t:n;..n.-. r-.—.rm.-.|
- " : ' r lii'w M.=|n:|r]r-r'r::-" 'C-L' |.|I'.:I':|I‘5IJE
ECU Upgrade I
“Era-Italic!“
L h fi fl l fl - M h l l fl h fl m
LflflWflfiuUI-Iflfimflhuflnm
lflhflmflnhflunhfimw
|[I Register
Lip-Hm Tredment
Data Tmaiment
lnspeclim.'Tesl
"-fl-flflflflflfifiw
" W
(NOTICE:-
IF TD” WT,
THE SYSTEM DUES MDT WORK.
6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1665
ECU Upgrade
-I Curr-I'll: H fl l l fl -
- Lulu-1lie-III: Emmmefifinn
I fi fl m
*DIHIHLIEIIIIII'III'I-la. Elam-u hielnriupru-Hlu.
‘ I fl fl r fl m fl m fl m fl h m m
13DDHGTep-erm'mlfluemflm
fl fl fl m w w fi n d h m l fi m } .
fiflflflflTmfihVflIwmflflT-inmnmmm.
IE1 Register iJDflHflTmhenmhflmuIGm-fi
fiDDHflT-e-Pu'ltl mini-Iii.- trim-131:“
Dtn m m { u m m m j
Dena Train-ant
Imp-amen .| Test
update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1666
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
EAlEAL
:P::DE AIDDEL :PHAIAE :PTTAIE Pm MATURE :AU3E
TP: PEPLA:E
“:13!":2: 3. E:1I.1 UPDATE 3.331131 ETIEPF
331m I ”5“”
1111—1131111r
I-I= 3.3L 3.TF5 REPLACE
E:111 UPDATE
1:A11} 3.3IUH 33133-
3:133PFF
cums-a: 33mm: m
Tfltflh {chm 3:1”FF
331113P113
um m 33.33
:13I a em{”44“} TP: RE'LAGE
TP: REPLA:E
w : 3. E:1I.1 UPDATE DJIUI-I 3;5$;F H“ :1:
' {Ii-LINE}
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1674
Frant
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1675
mm ID
MODELTEAR 5;: I I nms
FRE'UIDUE
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HFTH33*52AETF#¢E needed hr meee 3 nun
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nrrnsrszesmm
3333M? unflwsmmm
HHH33-33333H333
33113- "31333333313133
3:334 unueatszesmnep "Hum-335mm
"Hm—333333333
HFflH—STEEAEBJHM
HFflHBTEiASfl-IAM
33113- "Famrsmsmnm
23mm 33333 HFflflaa‘SEASflJADA Hflflmm
HFBH33*$2A5«BJFBA
HFEHETSEAEBJHEA
HFEHETSEASEJHBA
3313333r 33113—
33333 HFEHEE'EEAEEJHM
HFEH33'52AEBJHBA "Film-333333333
it...
EhhihiarmrrFtn-
«mm
tile}.r teaching
3"" "I”
“a”writing
With
{EU-BTW) 391flfi-
3mm . n
EHEHfl-B hi2 THE“ EHrrietr-Mr'timh, pmmdumfi
required
EH?"3-‘B*M2"BJHA‘
EH7"33*M2“BJHB" -
EN?“3£*ME“BJHD‘
mm“ 351”6'
t“
EHEH33*52"TF4G‘
EHENJB*32"?F4E* EHTHI-B‘BP'EJHA'
m-
“WNW
mun"
{warm 30450
Emnaetszttemilr
EHi'Hae-ezt-eJHe' -
EHi'Hee-sr—EJHD'
EN?N33*M2**TG33*
ENTN3fl*M2**TG:iG*
Emuae-ME-wnh' menarnrrmnt
With entue— EWHSB‘ME“?J1A*
{2003mm 3cm ENEN38*M2**8JVA*
Ehieneathtz-temr
EHBHEE‘MT‘BJHC‘ Enumermr-WWN
EHEHSB'ME'*BJHJ*
Eitmeiitezttreae-
mm“
[tiehm 391“5'
3mm
M M mwm
EHrHee-ez-tntm
emnea-srtemm on“,
EHBM33*32"BJHG* ENBHH‘EP'W“
EHENJB*$2**BJHJ*
EHThiee-Mzt-rJtet
Ettrhiaeriuizttntet EHBNEE'MF'BJIB‘
With 391flfi- fiflflfl‘MFWF
{EWEWJ 36412 ENEMEE*M2“BJHB‘
EHBNBB‘MT‘BJHD‘ enemas-ureter?
EHBH33*M2"BJHH'
Hummer-rue" Emmyflflum
Withuut etime- Ettmaetezttnzet
ten-new) 3G4— EHBtiaB. $2__BJHE‘
EHEH33*52“EJHD* ENEMEE”52“HJWB‘
Etienne-ertiunitt
NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1681
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1682
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1683
Tm: I: pun-gran for updltlng EDI.
Darn llll‘llfll a m [In-gm. durum flu upflh.
I] I 3
5%
ROM ID Reading...
4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1684
I«'Iehuirflle 51W Management
m J || .‘U-r'lll' r.41.':‘-1:'II'IT.'-; 3 ."ir'II'IIHI". ;. Fr.;.r.-...-t:n;..n.-. r-.—.rm.-.|
- " : ' r lii'w M.=|n:|r]r-r'r::-" 'C-L' |.|I'.:I':|I‘5IJE
ECU Upgrade I
“Era-Italic!“
L h fi fl l fl - M h l l fl h fl m
LflflWflfiuUI-Iflfimflhuflnm
lflhflmflnhflunhfimw
|[I Register
Lip-Hm Tredment
Data Tmaiment
lnspeclim.'Tesl
"-fl-flflflflflfifiw
" W
(NOTICE:-
IF TD” WT,
THE SYSTEM DUES MDT WORK.
6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1685
ECU Upgrade
-I Curr-I'll: H fl l l fl -
- Lulu-1lie-III: Emmmefifinn
I fi fl m
*DIHIHLIEIIIIII'III'I-la. Elam-u hielnriupru-Hlu.
‘ I fl fl r fl m fl m fl m fl h m m
13DDHGTep-erm'mlfluemflm
fl fl fl m w w fi n d h m l fi m } .
fiflflflflTmfihVflIwmflflT-inmnmmm.
IE1 Register iJDflHflTmhenmhflmuIGm-fi
fiDDHflT-e-Pu'ltl mini-Iii.- trim-131:“
Dtn m m { u m m m j
Dena Train-ant
Imp-amen .| Test
update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
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Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1686
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
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Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
3
Symbols Part 1
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Information and Instructions > Page 1698
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Symbols Part 2
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No
Start In P/N
Group TRANSAXLE
Number 09-AT-013
This TSB supersedes TSB 03-40-013 to add repair information (Steps 2-3).
DESCRIPTION:
An improperly adjusted or improperly operating range switch may result in the following conditions:
This TSB provides information concerning the proper adjustment and diagnosis of the transaxle
range switch.
PARTS INFORMATION
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Technical Service Bulletins > Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No
Start In P/N > Page 1716
MODEL OPERA“ MATURE
TIME CODE cane
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WARRANTY INFORMATION
Service Procedure
1. Attach a GDS and check for DTC in both the "Engine" and "Automatic Transaxle" menus. Go to
Step 2 for 2000-02 Accent or Step 3 for 2006-Sonata. For other vehicles, go to Step 4.
a. Check the rear combination lamp ground bolts for tightness and good electrical contact (refer to
applicable ETM, "Tail, Parking & License Lamps" section). Go to Step b.
b. For 2006-Sonata: Remove the center console cover and check for contamination on the M40
connector to the sports mode switch. If so, clean and repair the connector as necessary. Go to step
c below.
c. For 2006-07 Sonata: Remove the front pillar cover and verify the harness is properly routed near
the clip. Repair the harness as necessary. Go to Step 4.
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Technical Service Bulletins > Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No
Start In P/N > Page 1717
SHIFI' LEVER 603
P PIN
R R
N PIN
D D
4. Attach a GDS and select vehicle, "A/T" menu, "Current Data" and "Shift Lever Switch".
5. Move the shift lever and confirm the GDS reads the gear shift position as shown above. If so, the
harness currently does not have an open or short circuit between. the PCM/TCM and range switch.
7. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If so, go to Step 8
^ If not, go to Step 11
8. Inspect the connector to the range switch for a bent pin or pin not fully inserted and related
wiring for an open or short circuit. If OK, follow the repair procedure below:
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Start In P/N > Page 1718
Insert M5 um: I
10. Attach the lever and nut. Tighten the nut to specification. Go to Step 11.
13. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification. Remove the 5mm drill or M5 bolt.
14. Move the shift lever to the "N" position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
16. Drive the vehicle two key-on to key-off drive cycles, including shifting to gears D, 3, 2, L (if
equipped) and R. If the:
^ DTC resets, repair or replace the control harness. If the DTC sets again, replace the TCM.
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Technical Service Bulletins > Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode'
Transmission Position Switch/Sensor: Customer Interest A/T - Won't Shift In 'D', Shifts in 'Sports
Mode'
Group: TRANSAXLE
Number: 06-40-013
Model: 2001 ~ SANTA FE & XG, 2002 ~ SONATA, 2003 ~ TIBURON, 2005 ~ TUCSON, 2006 ~
AZERA
DESCRIPTION:
If you are servicing a vehicle equipped with a "SHIFTRONIC(TM)" automatic transaxle that has the
following symptoms, refer to the repair procedure shown below:
^ Will not shift in "D" position, but shifts correctly in "Sports Mode"
TEST PROCEDURE:
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With ignition key "ON" and engine off, select "Sports Mode Select Switch."
Check the operation of the select switch when the shift lever is moved from "D" to "Sports Mode"
and back.
Select:
^ F2, "SCRN" two times (this will isolate top two data to provide a quick refresh rate)
Shift the Sports Mode lever to the upshift and downshift positions and check the operation of the
switches:
SWITCH BOX REPLACEMENT (2001~SANTA FE & XG, 2002 SONATA & 2003 TIBURON):
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Technical Service Bulletins > Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' >
Page 1725
If the switches do not operate as shown above, proceed as follows:
1. Refer to the appropriate shop manual, "Body" section and remove the center console.
2. Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
3. Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and
replace the switch box assembly.
GEAR SHIFT LEVER REPLACEMENT (2006 SONATA & AZERA, 2007 SANTA FE):
^ Refer to the appropriate shop manual, 'Body" section, to remove the center console.
^ Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
^ Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and replace
the gear shift lever assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' >
Page 1726
PART NAME
Eflflfln-flfi Ennata
Eflfl1~flfl Santa Fe
Eflfl1~fl5 IGBflDflfifl Smith bu: Easy
EBD3~ T||:Iurun 4ET4D-2U1Dfl
2flflfi~ Tumun #E?ED—2Eflflfl
EQUEH Eunata
46H [II-3 Hflflfl
Eflflfi~ Azera
Gan" shift lava
EflD?~ Ea ntEI FE 4ET1U-EE1UU
EWHE Sunata
2m1-flfl Santa Fe 45?4fl-39I‘.|flfl
2M1-fl5 mammal:
NEE G31
45T4D-2G1DID
fiTflfl-EEHI}
4ET1fl-3Hfl'flfl
PARTS INFORMATION:
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE'
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DIG are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
m
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E
5
I
m
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
LE BflLlHflID BUT!
[III HELENE!!! BUT!
EHD BELEHIIIII DUI!
02D BflLlHflIll BUT!
BED EDLEHHID DUI!
flIL IMPEBHIUEE
SHIFT POEITIDH
8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' >
Page 1733
1. 2 CURRENT IH-‘I‘I'FI
l H H H - H ‘ H
an EDIE”!!! Ell"!
fllL I w m m
'1
SHIFT PflSITIfl'I
"5'1 T: T.. T'I1'Z T L Flt-T F: FH-J.
l-‘IH I - I m l m l m l m -
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' >
Page 1734
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
Group TRANSAXLE
Number 09-AT-013
This TSB supersedes TSB 03-40-013 to add repair information (Steps 2-3).
DESCRIPTION:
An improperly adjusted or improperly operating range switch may result in the following conditions:
This TSB provides information concerning the proper adjustment and diagnosis of the transaxle
range switch.
PARTS INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul >
09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 1740
MODEL OPERA“ MATURE
TIME CODE cane
IDDFDB Elantm Sudan
1BBE~D5 Sunni-a
Ill
2m3~ lumn
“5
2m1~ [15 JILGEDD
EDDE~ Accent
2306*- Mara 4270mm C15
BEEF- Elantra Sedan
2DDE~ Elantra Taming
[LB
EDDF Entuuragu
2m1~ Santa Fa
20W- Sunata
EDGE- Tumn
All EDS
m m I13
umfinn
a t pillar
EMF
WARRANTY INFORMATION
Service Procedure
1. Attach a GDS and check for DTC in both the "Engine" and "Automatic Transaxle" menus. Go to
Step 2 for 2000-02 Accent or Step 3 for 2006-Sonata. For other vehicles, go to Step 4.
a. Check the rear combination lamp ground bolts for tightness and good electrical contact (refer to
applicable ETM, "Tail, Parking & License Lamps" section). Go to Step b.
b. For 2006-Sonata: Remove the center console cover and check for contamination on the M40
connector to the sports mode switch. If so, clean and repair the connector as necessary. Go to step
c below.
c. For 2006-07 Sonata: Remove the front pillar cover and verify the harness is properly routed near
the clip. Repair the harness as necessary. Go to Step 4.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul >
09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 1741
SHIFI' LEVER 603
P PIN
R R
N PIN
D D
4. Attach a GDS and select vehicle, "A/T" menu, "Current Data" and "Shift Lever Switch".
5. Move the shift lever and confirm the GDS reads the gear shift position as shown above. If so, the
harness currently does not have an open or short circuit between. the PCM/TCM and range switch.
7. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If so, go to Step 8
^ If not, go to Step 11
8. Inspect the connector to the range switch for a bent pin or pin not fully inserted and related
wiring for an open or short circuit. If OK, follow the repair procedure below:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul >
09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 1742
Insert M5 um: I
10. Attach the lever and nut. Tighten the nut to specification. Go to Step 11.
13. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification. Remove the 5mm drill or M5 bolt.
14. Move the shift lever to the "N" position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
16. Drive the vehicle two key-on to key-off drive cycles, including shifting to gears D, 3, 2, L (if
equipped) and R. If the:
^ DTC resets, repair or replace the control harness. If the DTC sets again, replace the TCM.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1720307-02 >
Mar > 07 > A/T Controls - Neutral Position Switch Adaptive Relearn
H Pmcnrlum Nnt Pttrlttrnterl Pastel blue II.':nnI1|tlnr1
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Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - Neutral
Position Switch Adaptive Relearn
Resetting Adaptive Learning and Range Switch Neutral Position Learning
If the transaxle or transaxle control unit is replaced, the TCU adaptive learning values must be
reset (erased) and the range switch neutral position must be relearned using either the GDS or
Hi-Scan Pro. If the following procedures are not completed, the following conditions may occur:
^ Stop the vehicle, move the shift lever to "P" and set the parking brake.
Follow the instructions on the screen and confirm the test indicates "Completed:"
Luci-5.9m nut
^ Stop the vehicle, move the shift lever to "N" and set the parking brake.
^ Loosen the nut on the shift cable. Align the dot (o) on the shift lever to the "N" mark on the TCU.
— ' — I _ I
-_-—-_I.I—H.l—.-—.In.—h-.
" - - - _ - ‘ . — i '
ll - . .- --'—:
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II—I-IIII-il-
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^ Follow the instructions on the screen and confirm the test indicates "Completed."
^ Move the shift lever from "P" to "D" and confirm the shift position indicator on the dash reads
correctly. Confirm the correct gear indication using the Hi-Scan or GDS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep >
06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode'
Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Won't Shift In 'D', Shifts
in 'Sports Mode'
Group: TRANSAXLE
Number: 06-40-013
Model: 2001 ~ SANTA FE & XG, 2002 ~ SONATA, 2003 ~ TIBURON, 2005 ~ TUCSON, 2006 ~
AZERA
DESCRIPTION:
If you are servicing a vehicle equipped with a "SHIFTRONIC(TM)" automatic transaxle that has the
following symptoms, refer to the repair procedure shown below:
^ Will not shift in "D" position, but shifts correctly in "Sports Mode"
TEST PROCEDURE:
A 2 I [I LEVEL, FiLI.
11H :TIHTEI-l
u'f WITH-l
'l' Ulfll' 311 "III
--n|'-;r_ m u m
”HI-1"? ”11!l III" 31-F—
..| j' Ih|:i| 1rlliu'H "Ll
Sports Mada
Select Switch
- "an SUITE“
'I ::.I.||III-.Il
-I Lr'l‘I-f 'El-III'IEII
- . " . E EHI‘IEH
-. HI-lF |I '-
With ignition key "ON" and engine off, select "Sports Mode Select Switch."
Check the operation of the select switch when the shift lever is moved from "D" to "Sports Mode"
and back.
Select:
^ F2, "SCRN" two times (this will isolate top two data to provide a quick refresh rate)
Shift the Sports Mode lever to the upshift and downshift positions and check the operation of the
switches:
SWITCH BOX REPLACEMENT (2001~SANTA FE & XG, 2002 SONATA & 2003 TIBURON):
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep >
06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' > Page 1755
If the switches do not operate as shown above, proceed as follows:
1. Refer to the appropriate shop manual, "Body" section and remove the center console.
2. Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
3. Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and
replace the switch box assembly.
GEAR SHIFT LEVER REPLACEMENT (2006 SONATA & AZERA, 2007 SANTA FE):
^ Refer to the appropriate shop manual, 'Body" section, to remove the center console.
^ Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
^ Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and replace
the gear shift lever assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep >
06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' > Page 1756
PART NAME
Eflflfln-flfi Ennata
Eflfl1~flfl Santa Fe
Eflfl1~fl5 IGBflDflfifl Smith bu: Easy
EBD3~ T||:Iurun 4ET4D-2U1Dfl
2flflfi~ Tumun #E?ED—2Eflflfl
EQUEH Eunata
46H [II-3 Hflflfl
Eflflfi~ Azera
Gan" shift lava
EflD?~ Ea ntEI FE 4ET1U-EE1UU
EWHE Sunata
2m1-flfl Santa Fe 45?4fl-39I‘.|flfl
2M1-fl5 mammal:
NEE G31
45T4D-2G1DID
fiTflfl-EEHI}
4ET1fl-3Hfl'flfl
PARTS INFORMATION:
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 >
Nov > 05 > A/T - No Movement In Drive/Reverse
MODEL: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DTC in both the "Engine" and "Automatic Transaxle" menus:
^ If DTC are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to Step 9
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 >
Nov > 05 > A/T - No Movement In Drive/Reverse > Page 1761
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
shift cable to the lever and install the nut. Tighten the nut to specification.
. I ‘
“‘-
‘ "I'-
- ' fi .
__"-'I
"-1-.
H
l I!
Wu: I l m m l l m l l m l l m l l m fl
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 >
Nov > 05 > A/T - No Movement In Drive/Reverse > Page 1763
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
12. Install the A/T Tester, P/N 09450-AT000, to the vehicle:
^ Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottompan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an
^ If no problem is found swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse
WARRANTY INFORMATION:
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
m
h
E
5
I
m
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
LE BflLlHflID BUT!
[III HELENE!!! BUT!
EHD BELEHIIIII DUI!
02D BflLlHflIll BUT!
BED EDLEHHID DUI!
flIL IMPEBHIUEE
SHIFT POEITIDH
8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-40-016 > Oct >
05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 1770
1. 2 CURRENT IH-‘I‘I'FI
l H H H - H ‘ H
an EDIE”!!! Ell"!
fllL I w m m
'1
SHIFT PflSITIfl'I
"5'1 T: T.. T'I1'Z T L Flt-T F: FH-J.
l-‘IH I - I m l m l m l m -
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-40-016 > Oct >
05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 1771
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
1-
1m
.Jql
E {- .l Uhrllrfll-
i'r-J-‘Hur
lmnmmml
J huh— mile-I..-
“ m l h fl fl h fl l fl fl fl
“ H I - fl “ !
“ a n
Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - Neutral
Position Switch Adaptive Relearn
Resetting Adaptive Learning and Range Switch Neutral Position Learning
If the transaxle or transaxle control unit is replaced, the TCU adaptive learning values must be
reset (erased) and the range switch neutral position must be relearned using either the GDS or
Hi-Scan Pro. If the following procedures are not completed, the following conditions may occur:
^ Stop the vehicle, move the shift lever to "P" and set the parking brake.
Follow the instructions on the screen and confirm the test indicates "Completed:"
Luci-5.9m nut
^ Stop the vehicle, move the shift lever to "N" and set the parking brake.
^ Loosen the nut on the shift cable. Align the dot (o) on the shift lever to the "N" mark on the TCU.
— ' — I _ I
-_-—-_I.I—H.l—.-—.In.—h-.
" - - - _ - ‘ . — i '
ll - . .- --'—:
‘1 ill. l — — *
i i |-I-'I-|I
II—I-IIII-il-
I--IIfl"'1II-ln Ir_-|-I-I.
- - - -
E. a nm
II. I'll“I “ .
H. m m ! 'l‘fll'
I5. alarm
5 . FREE! PET-I'll HII'FI
IT. FIGHTING fll'l'fl I'd"! m
^ Follow the instructions on the screen and confirm the test indicates "Completed."
^ Move the shift lever from "P" to "D" and confirm the shift position indicator on the dash reads
correctly. Confirm the correct gear indication using the Hi-Scan or GDS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-016 > Aug > 09
> A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh Engagement
MODEL: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DTC in both the "Engine" and "Automatic Transaxle" menus:
^ If DTC are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to Step 9
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-016 > Aug > 09
> A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh Engagement > Page 1783
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
shift cable to the lever and install the nut. Tighten the nut to specification.
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^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-016 > Aug > 09
> A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh Engagement > Page 1785
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
12. Install the A/T Tester, P/N 09450-AT000, to the vehicle:
^ Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottompan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an
^ If no problem is found swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse
WARRANTY INFORMATION:
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component
Locations > Page 1790
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1793
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1796
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1797
35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1798
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1799
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1801
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1802
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1803
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1804
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1805
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1806
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1807
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1808
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Connector Views: The Connector Pin Out Views for connectors shown on these diagrams can be
found on the Connector Pin Out images that follow most sets of system diagrams.
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1. Connect the positive (+) lead from battery to terminal 1 and negative (-) lead to terminal 2. 2.
Connect the positive (+) lead from tester to terminal 3 and the negative (-) lead to terminal 2. 3.
Rotate the shaft. 4. Check that there is voltage change from approx. 0 V to 11 V or more between
terminals 3 and 2.
5. The voltage change should be 4 times for every revolution of the speed sensor shaft.
REPLACEMENT
1. Disconnect the vehicle speed sensor connector (B). 2. Remove the bolt (10 mm [0.4 inch]). 3.
Inspect the vehicle speed sensor bore.
3. Inspect the O-ring for nicks or cut. Install a new O-ring as necessary. 4. Apply a light coat of
automatic transaxle fluid to the O-ring seal before installation. 5. Install the vehicle speed sensor. 6.
Connect the vehicle speed sensor connector. 7. Installation is the reverse of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor: > 10-EE-002 > Jul > 10 > Engine Controls -
MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
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PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor: > 07-36-006 > Sep > 07 > Engine Controls -
Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - Low Power/MIL ON/DTC
P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
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PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Accelerator Pedal Position Sensor: > 10-EE-002 > Jul > 10 > Engine
Controls - MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
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PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Accelerator Pedal Position Sensor: > 07-36-006 > Sep > 07 > Engine
Controls - Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - Low
Power/MIL ON/DTC P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
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WARRANTY INFORMATION
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Service Bulletins > Page 1842
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Service Bulletins > Page 1844
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Overview
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 1845
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 1846
DEECRIPTIDH emu:
Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
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Service Bulletins > Page 1847
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Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
Specification
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Service Bulletins > Page 1848
SCHEHATIE DMHAH
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Schematic Diagram
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications
Detail
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 1853
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 1854
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Information and Instructions > Page 1857
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Information and Instructions > Page 1860
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Information and Instructions > Page 1861
35
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Symbols Part 1
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Information and Instructions > Page 1862
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Information and Instructions > Page 1863
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
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SPECIFICATION
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Air Flow Meter/Sensor: Testing and Inspection
DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
Specification
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SGHEHATI‘E m m
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Schematic Diagram
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2135/P0638
Group: FUEL SYSTEM
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1883
Frant
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1884
mm ID
MODELTEAR 5;: I I nms
FRE'UIDUE
HF?H33*52ASTF4BB HDTE: mnwfiune
HFTH33*52AETF#¢E needed hr meee 3 nun
33113- HFTHEE'EEASTGEEA
nrrnsrszesmm
3333M? unflwsmmm
HHH33-33333H333
33113- "31333333313133
3:334 unueatszesmnep "Hum-335mm
"Hm—333333333
HFflH—STEEAEBJHM
HFflHBTEiASfl-IAM
33113- "Famrsmsmnm
23mm 33333 HFflflaa‘SEASflJADA Hflflmm
HFBH33*$2A5«BJFBA
HFEHETSEAEBJHEA
HFEHETSEASEJHBA
3313333r 33113—
33333 HFEHEE'EEAEEJHM
HFEH33'52AEBJHBA "Film-333333333
it...
EhhihiarmrrFtn-
«mm
tile}.r teaching
3"" "I”
“a”writing
With
{EU-BTW) 391flfi-
3mm . n
EHEHfl-B hi2 THE“ EHrrietr-Mr'timh, pmmdumfi
required
EH?"3-‘B*M2"BJHA‘
EH7"33*M2“BJHB" -
EN?“3£*ME“BJHD‘
mm“ 351”6'
t“
EHEH33*52"TF4G‘
EHENJB*32"?F4E* EHTHI-B‘BP'EJHA'
m-
“WNW
mun"
{warm 30450
Emnaetszttemilr
EHi'Hae-ezt-eJHe' -
EHi'Hee-sr—EJHD'
EN?N33*M2**TG33*
ENTN3fl*M2**TG:iG*
Emuae-ME-wnh' menarnrrmnt
With entue— EWHSB‘ME“?J1A*
{2003mm 3cm ENEN38*M2**8JVA*
Ehieneathtz-temr
EHBHEE‘MT‘BJHC‘ Enumermr-WWN
EHEHSB'ME'*BJHJ*
Eitmeiitezttreae-
mm“
[tiehm 391“5'
3mm
M M mwm
EHrHee-ez-tntm
emnea-srtemm on“,
EHBM33*32"BJHG* ENBHH‘EP'W“
EHENJB*$2**BJHJ*
EHThiee-Mzt-rJtet
Ettrhiaeriuizttntet EHBNEE'MF'BJIB‘
With 391flfi- fiflflfl‘MFWF
{EWEWJ 36412 ENEMEE*M2“BJHB‘
EHBNBB‘MT‘BJHD‘ enemas-ureter?
EHBH33*M2"BJHH'
Hummer-rue" Emmyflflum
Withuut etime- Ettmaetezttnzet
ten-new) 3G4— EHBtiaB. $2__BJHE‘
EHEH33*52“EJHD* ENEMEE”52“HJWB‘
Etienne-ertiunitt
NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1890
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1891
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1892
Tm: I: pun-gran for updltlng EDI.
Darn llll‘llfll a m [In-gm. durum flu upflh.
I] I 3
5%
ROM ID Reading...
4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1893
I«'Iehuirflle 51W Management
m J || .‘U-r'lll' r.41.':‘-1:'II'IT.'-; 3 ."ir'II'IIHI". ;. Fr.;.r.-...-t:n;..n.-. r-.—.rm.-.|
- " : ' r lii'w M.=|n:|r]r-r'r::-" 'C-L' |.|I'.:I':|I‘5IJE
ECU Upgrade I
“Era-Italic!“
L h fi fl l fl - M h l l fl h fl m
LflflWflfiuUI-Iflfimflhuflnm
lflhflmflnhflunhfimw
|[I Register
Lip-Hm Tredment
Data Tmaiment
lnspeclim.'Tesl
"-fl-flflflflflfifiw
" W
(NOTICE:-
IF TD” WT,
THE SYSTEM DUES MDT WORK.
6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1894
ECU Upgrade
-I Curr-I'll: H fl l l fl -
- Lulu-1lie-III: Emmmefifinn
I fi fl m
*DIHIHLIEIIIIII'III'I-la. Elam-u hielnriupru-Hlu.
‘ I fl fl r fl m fl m fl m fl h m m
13DDHGTep-erm'mlfluemflm
fl fl fl m w w fi n d h m l fi m } .
fiflflflflTmfihVflIwmflflT-inmnmmm.
IE1 Register iJDflHflTmhenmhflmuIGm-fi
fiDDHflT-e-Pu'ltl mini-Iii.- trim-131:“
Dtn m m { u m m m j
Dena Train-ant
Imp-amen .| Test
update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 1895
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
EAlEAL
:P::DE AIDDEL :PHAIAE :PTTAIE Pm MATURE :AU3E
TP: PEPLA:E
“:13!":2: 3. E:1I.1 UPDATE 3.331131 ETIEPF
331m I ”5“”
1111—1131111r
I-I= 3.3L 3.TF5 REPLACE
E:111 UPDATE
1:A11} 3.3IUH 33133-
3:133PFF
cums-a: 33mm: m
Tfltflh {chm 3:1”FF
331113P113
um m 33.33
:13I a em{”44“} TP: RE'LAGE
TP: REPLA:E
w : 3. E:1I.1 UPDATE DJIUI-I 3;5$;F H“ :1:
' {Ii-LINE}
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1903
Frant
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1904
mm ID
MODELTEAR 5;: I I nms
FRE'UIDUE
HF?H33*52ASTF4BB HDTE: mnwfiune
HFTH33*52AETF#¢E needed hr meee 3 nun
33113- HFTHEE'EEASTGEEA
nrrnsrszesmm
3333M? unflwsmmm
HHH33-33333H333
33113- "31333333313133
3:334 unueatszesmnep "Hum-335mm
"Hm—333333333
HFflH—STEEAEBJHM
HFflHBTEiASfl-IAM
33113- "Famrsmsmnm
23mm 33333 HFflflaa‘SEASflJADA Hflflmm
HFBH33*$2A5«BJFBA
HFEHETSEAEBJHEA
HFEHETSEASEJHBA
3313333r 33113—
33333 HFEHEE'EEAEEJHM
HFEH33'52AEBJHBA "Film-333333333
it...
EhhihiarmrrFtn-
«mm
tile}.r teaching
3"" "I”
“a”writing
With
{EU-BTW) 391flfi-
3mm . n
EHEHfl-B hi2 THE“ EHrrietr-Mr'timh, pmmdumfi
required
EH?"3-‘B*M2"BJHA‘
EH7"33*M2“BJHB" -
EN?“3£*ME“BJHD‘
mm“ 351”6'
t“
EHEH33*52"TF4G‘
EHENJB*32"?F4E* EHTHI-B‘BP'EJHA'
m-
“WNW
mun"
{warm 30450
Emnaetszttemilr
EHi'Hae-ezt-eJHe' -
EHi'Hee-sr—EJHD'
EN?N33*M2**TG33*
ENTN3fl*M2**TG:iG*
Emuae-ME-wnh' menarnrrmnt
With entue— EWHSB‘ME“?J1A*
{2003mm 3cm ENEN38*M2**8JVA*
Ehieneathtz-temr
EHBHEE‘MT‘BJHC‘ Enumermr-WWN
EHEHSB'ME'*BJHJ*
Eitmeiitezttreae-
mm“
[tiehm 391“5'
3mm
M M mwm
EHrHee-ez-tntm
emnea-srtemm on“,
EHBM33*32"BJHG* ENBHH‘EP'W“
EHENJB*$2**BJHJ*
EHThiee-Mzt-rJtet
Ettrhiaeriuizttntet EHBNEE'MF'BJIB‘
With 391flfi- fiflflfl‘MFWF
{EWEWJ 36412 ENEMEE*M2“BJHB‘
EHBNBB‘MT‘BJHD‘ enemas-ureter?
EHBH33*M2"BJHH'
Hummer-rue" Emmyflflum
Withuut etime- Ettmaetezttnzet
ten-new) 3G4— EHBtiaB. $2__BJHE‘
EHEH33*52“EJHD* ENEMEE”52“HJWB‘
Etienne-ertiunitt
NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1910
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1911
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1912
Tm: I: pun-gran for updltlng EDI.
Darn llll‘llfll a m [In-gm. durum flu upflh.
I] I 3
5%
ROM ID Reading...
4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1913
I«'Iehuirflle 51W Management
m J || .‘U-r'lll' r.41.':‘-1:'II'IT.'-; 3 ."ir'II'IIHI". ;. Fr.;.r.-...-t:n;..n.-. r-.—.rm.-.|
- " : ' r lii'w M.=|n:|r]r-r'r::-" 'C-L' |.|I'.:I':|I‘5IJE
ECU Upgrade I
“Era-Italic!“
L h fi fl l fl - M h l l fl h fl m
LflflWflfiuUI-Iflfimflhuflnm
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IF TD” WT,
THE SYSTEM DUES MDT WORK.
6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
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Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1914
ECU Upgrade
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update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
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Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 1915
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
EAlEAL
:P::DE AIDDEL :PHAIAE :PTTAIE Pm MATURE :AU3E
TP: PEPLA:E
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Information and Instructions
THEE: -
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Information and Instructions > Page 1922
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
wfif?)@:mmmmmmrul2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Information and Instructions > Page 1925
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 1926
35
3
Symbols Part 1
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Information and Instructions > Page 1927
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Symbols Part 2
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Information and Instructions > Page 1928
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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murmur wuss M
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EEHFEIIIA
Camshaft Position Sensor: Component Locations
Bank 1
Bank 2
'-
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Page 1943
311T
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Overview
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Page 1944
PHOTO.35
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1947
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
wfif?)@:mmmmmmrul2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Instructions > Page 1950
E .
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1951
35
3
Symbols Part 1
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Instructions > Page 1952
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1953
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1955
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1956
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1957
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Instructions > Page 1958
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1959
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1960
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1961
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1962
DESCRIPTION Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft
position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects
the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which out- put voltage changes when magnetic field is made on the IC with
current flow. So the sequential injection of the 6 cylinders is impossible without CMPS signal.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1963
DESCRIPTION Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft
position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects
the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which out- put voltage changes when magnetic field is made on the IC with
current flow. So the sequential injection of the 6 cylinders is impossible without CMPS signal.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1964
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Schematic Diagram
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1968
Detail
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Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Instructions > Page 1971
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Instructions > Page 1974
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1975
35
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Symbols Part 1
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1976
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1977
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1979
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1980
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1981
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Instructions > Page 1982
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 1983
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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DESCRIPTION Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of
the most important sensors of the engine control system. If there is no CKPS signal input, fuel is
not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal.
This sensor is installed on transaxle housing and generates alternating current by magnetic flux
field which is made by the sensor and the target wheel when engine runs. The magnetic flux
increases when the protrusion of the target wheel is getting near to the sensor and does not
change in the most close position. When the protrusion becomes estranged from the sensor,
magnetic flux disappears and alternating current is generated. The target wheel consists of 58 slots
and 2 missing slots on 360 CA (Crank Angle).
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DESCRIPTION Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of
the most important sensors of the engine control system. If there is no CKPS signal input, fuel is
not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal.
This sensor is installed on transaxle housing and generates alternating current by magnetic flux
field which is made by the sensor and the target wheel when engine runs. The magnetic flux
increases when the protrusion of the target wheel is getting near to the sensor and does not
change in the most close position. When the protrusion becomes estranged from the sensor,
magnetic flux disappears and alternating current is generated. The target wheel consists of 58 slots
and 2 missing slots on 360 CA (Crank Angle).
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EGEEHATIG DIAGRAM
Schematic Diagram
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Ignition Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
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Symbols Part 1
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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INSPECTION
1. Disconnect the ignition switch connector and key warning switch connector from under the
steering column. 2. Check for continuity between the terminals. 3. If continuity is not specified,
replace the switch.
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Ignition Switch: Service and Repair
REPLACEMENT
3. Remove the ignition switch (A) after loosening the screw and disconnecting the 6P connector. 4.
Remove the steering column shaft.
5. Remove the key warning switch and key illumination lamp (A) after loosening the screws and
disconnecting the 6P connector.
6. If it is necessary to remove the key lock cylinder (A), Remove the key lock cylinder (A) after
pushing lock pin (B) with key ON. 7. Installation is the reverse of removal procedure.
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Knock Sensor: Connector Locations
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SPEC IFEATI-DH
Specification
DESCRIPTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine
damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the
V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is
applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the
knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing.
This sequential control can improve engine power, torque and fuel economy.
Item.......................................................................................................................................................
..............................................................Specification
Capacitance..........................................................................................................................................
..........................................................1,480 - 2,220 pF
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EPEL' IFEATI-DH
EPEBIFIEA'I'IDH
Specification
DESCRIPTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine
damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the
V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is
applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the
knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing.
This sequential control can improve engine power, torque and fuel economy.
Specification
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EEHEHATIG MAE-RAH
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Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Component Locations
Components
Components
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Component Locations > Page 2025
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Impact Sensor: Connector Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Diagram Information and Instructions
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Impact Sensor: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2028
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Component Information > Diagrams > Diagram Information and Instructions > Page 2031
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2032
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2033
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Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2034
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Component Information > Diagrams > Diagram Information and Instructions > Page 2037
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2039
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Component Information > Diagrams > Diagram Information and Instructions > Page 2041
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Description and Operation > Front Impact Sensor
Impact Sensor: Description and Operation Front Impact Sensor
DESCRIPTION
The front impact sensors (FIS) are installed inside the member inner. They are remote sensors that
detect acceleration due to collision at their mounting locations. The primary purpose of the Front
Impact Sensor (FIS) is to provide an indication of a collision. the Front Impact Sensor(FIS) sends
acceleration data to the SRSCM.
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Component Information > Description and Operation > Front Impact Sensor > Page 2045
Impact Sensor: Description and Operation Side Impact Sensor
DESCRIPTION
The Side Impact Sensor (SIS) system consist of two front SIS which are installed inside the B-Pillar
(LH and RH). They are remote sensors that detect acceleration due to collision at their mounting
locations. The primary purpose of the Side Impact Sensor (SIS) is to provide an indication of a
collision. The Side Impact Sensor (SIS) sends acceleration data to the SRSCM.
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Component Information > Service and Repair > Front Impact Sensor
REMOVAL
CAUTION:
- Before disconnecting the front impact sensor connector, disconnect the front airbag connector(s).
- Do not turn the ignition switch ON and do not connect the battery cable while replacing the front
impact sensor.
1. Disconnect the negative battery cable, and wait at least three minutes before beginning work.
2. Remove the bolt(A) then remove the front impact sensor(B). 3. Installation is the reverse of
removal.
NOTE: After installing the front impact sensor, confirm proper system operation: Turn the ignition
switch ON: the SRS indicator light should turn on for about six seconds and then go off.
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Component Information > Service and Repair > Front Impact Sensor > Page 2048
REMOVAL
CAUTION:
- Removal of the airbag must be performed according to the precautions/ procedures described
previously.
- Before disconnecting the side impact sensor connector(s), disconnect the side airbag
connector(s).
- Do not turn the ignition switch ON and do not connect the battery cable while replacing the side
impact sensor.
1. Disconnect the negative battery cable, and wait at least three minutes before beginning work. 2.
Remove the front door scuff trim. 3. Remove the center pillar trim.
4. Remove the bolt(A) then remove the side impact sensor (B).
INSTALLATION
CAUTION:
- Be sure to install the harness wires so that they are not pinched or interfere with other parts.
- Do not turn the ignition switch ON and do not connect the battery cable while replacing the side
impact sensor.
1. Install the new side impact sensor with the bolt then connect the SRS harness connector to the
side impact sensor. 2. Reinstall the belt pretensioner. 3. Reconnect the negative battery cable 4.
After installing the side impact sensor, confirm proper system operation: Turn the ignition switch
ON: the SRS indicator light should turn on about
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle
Switch > Component Information > Locations > Page 2054
Seat Belt Buckle Switch: Description and Operation
DESCRIPTION
The buckle status shall modify the SRSCM deployment. If the Buckle Status is Unbuckled, the
corresponding pretensioner will be deactivated.
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Switch > Component Information > Locations > Page 2055
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Seat Belt Buckle Switch: Service and Repair
REPLACEMENT
2. After loosening the seat assembly mounting bolt and nut, remove the seat assembly (B). 3.
Remove the wire harness of buckle from seat.
4. Remove the seat belt buckle (A). 5. Installation is the reverse of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor
> Component Information > Technical Service Bulletins > Recalls: > NHTASA08V161000 > Apr > 08 > Recall 08V161000:
Air Bag System Defect
Seat Occupant Sensor: Recalls Recall 08V161000: Air Bag System Defect
MAKE/MODELS: MODEL/BUILD YEARS: Hyundai/Sonata 2006-2008 MANUFACTURER :
Hyundai-KIA America Technical Center Inc.
SUMMARY: Hyundai is recalling 393,714 M/Y 2006-2008 Sonata vehicles equipped with an
advanced air bag system which features an Occupant Classification System (OCS) in the right front
seat. The purpose of the OCS is to disable the right passenger seat front air bag when it detects
the presence of a child restraint system or small child in the right front seat. The right front air bag
is disabled to prevent injuries to a child that may result from a right front air bag inflation during a
crash.
CONSEQUENCE: Misclassification of a small stature adult as a child in the right front passenger
seat may cause the right front air bag to not inflate in an accident that merits air bag deployment
and may result in injury to the right front occupant.
REMEDY: Dealers will verify that the OCS does not properly recognize a properly seated adult
occupant. After verification, dealers will remove the right front seat cushion assembly and ship it to
an evaluation and repair facility. This facility will evaluate and repair or reprogram the seat cushion
and OCS as necessary. The recall is expected to begin on or about May 26, 2008. Owners may
contact Hyundai at 1-800-633-5151.
NOTES: Hyundai recall No. 083. Customers may contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to
http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor
> Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTASA08V161000 > Apr > 08
> Recall 08V161000: Air Bag System Defect
Seat Occupant Sensor: All Technical Service Bulletins Recall 08V161000: Air Bag System Defect
MAKE/MODELS: MODEL/BUILD YEARS: Hyundai/Sonata 2006-2008 MANUFACTURER :
Hyundai-KIA America Technical Center Inc.
SUMMARY: Hyundai is recalling 393,714 M/Y 2006-2008 Sonata vehicles equipped with an
advanced air bag system which features an Occupant Classification System (OCS) in the right front
seat. The purpose of the OCS is to disable the right passenger seat front air bag when it detects
the presence of a child restraint system or small child in the right front seat. The right front air bag
is disabled to prevent injuries to a child that may result from a right front air bag inflation during a
crash.
CONSEQUENCE: Misclassification of a small stature adult as a child in the right front passenger
seat may cause the right front air bag to not inflate in an accident that merits air bag deployment
and may result in injury to the right front occupant.
REMEDY: Dealers will verify that the OCS does not properly recognize a properly seated adult
occupant. After verification, dealers will remove the right front seat cushion assembly and ship it to
an evaluation and repair facility. This facility will evaluate and repair or reprogram the seat cushion
and OCS as necessary. The recall is expected to begin on or about May 26, 2008. Owners may
contact Hyundai at 1-800-633-5151.
NOTES: Hyundai recall No. 083. Customers may contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to
http://www.safercar.gov.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: >
09-EM-005 > Jul > 09 > Engine Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor For ECM: All Technical Service Bulletins Engine Controls - Oil
Temperature Sensor Oil Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
^ Torque Wrench
^ Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
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> Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Occupant Sensor: >
09-EM-005 > Jul > 09 > Engine Controls - Oil Temperature Sensor Oil Leaks > Page 2081
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
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> Component Information > Locations > Occupant Classification Sensor (OCS)
Components
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> Component Information > Locations > Occupant Classification Sensor (OCS) > Page 2084
Components
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor
> Component Information > Description and Operation > Occupant Classification Sensor (OCS)
Seat Occupant Sensor: Description and Operation Occupant Classification Sensor (OCS)
DESCRIPTION
The system is intended to classify the occupancy status of the front passenger seat in a motor
vehicle based on the measured force on the bottom seat cushion.
The system also communicates to the SRSCM whether to allow or inhibit the deployment of the
passenger airbags and/or pretensioner based upon this status.
The System also measures dynamic responses of the occupant. This information is used to identify
when a child seat is cinched down tightly with the seat belt, and to also determine if the seat is
unoccupied.
However, the dynamic measurements are not intended, nor capable of monitoring the seating
position of the occupant, nor can they determine the proximity of the occupant to the inflator
modules.
The system should not be confused with an occupant p0sition recognition system, or any other
occupant proximity sensor.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor
> Component Information > Description and Operation > Occupant Classification Sensor (OCS) > Page 2087
Seat Occupant Sensor: Description and Operation Seat Track Position Sensor
DESCRIPTION
The STPS operated via a non-contacting magnetic proximity sensing device combined with a
simple electronic circuit resulting in the ability of producing two separate and distinct logic level
signals. The STPS output signal is altered by the proximity of a separate ferro-magnetic shunt,
which is linked via the seat-track. The logic signal produced is the result of the proximity device
being activated (shunt present) or deactivated (no shunt present). When the seat is in the forward
position zone of the track, the sensor gives a low current (airbag inflator 2nd stage prohibit) signal.
When the seat is in the rear position zone of the track, it gives a high current (airbag inflator 2nd
stage enable) signal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor
> Component Information > Service and Repair > Occupant Classification Sensor (OCS)
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REPLACEMENT
2. After loosening the passenger seat assembly mounting bolt and nut, remove the seat assembly
(B). 3. Remove the seat cushion.
4. After removing the hogring clip(A) on the front of seat cushion and remove the seat cushion
cover(B).
Seat Occupant Sensor: Service and Repair Seat Track Position Sensor
REPLACEMENT
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions
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Ignition Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2100
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2103
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2104
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2105
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2106
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2108
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2109
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2110
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2111
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2112
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2113
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 2114
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Page 2115
INSPECTION
1. Disconnect the ignition switch connector and key warning switch connector from under the
steering column. 2. Check for continuity between the terminals. 3. If continuity is not specified,
replace the switch.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Page 2116
Ignition Switch: Service and Repair
REPLACEMENT
3. Remove the ignition switch (A) after loosening the screw and disconnecting the 6P connector. 4.
Remove the steering column shaft.
5. Remove the key warning switch and key illumination lamp (A) after loosening the screws and
disconnecting the 6P connector.
6. If it is necessary to remove the key lock cylinder (A), Remove the key lock cylinder (A) after
pushing lock pin (B) with key ON. 7. Installation is the reverse of removal procedure.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 2122
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 2123
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - Steering
Angle Sensor Centering Procedure
Steering Angle Sensor: Technical Service Bulletins Steering - Steering Angle Sensor Centering
Procedure
Group: CHASSIS
Number: 05-50-003
DESCRIPTION:
All 2006 MY Sonata vehicles are equipped with Electronic Stability Control (ESC). The ESC system
contains a steering angle sensor, which measures the amount and rate of steering wheel input.
The steering angle sensor is used by the ESC to determine if brake or engine torque interventions
should be activated to help the driver.
The steering angle sensor requires calibration whenever the following occurs:
This bulletin provides a procedure to recalibrate the steering angle sensor using the Hi-Scan Pro.
NOTE:
Before starting procedure, make sure vehicle has ESC. Look for button on dash.
1. Vehicle alignment must meet the following requirements before steering angle calibration can be
started.
^ Roll the vehicle forward and backward on a flat level surface prior to calibration.
NOTE:
Leave the ignition key in the "OFF" position before starting the following procedure.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - Steering
Angle Sensor Centering Procedure > Page 2128
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2. Attach the Data Link Connector (DLC) cable to the Hi-Scan Pro main body and securely tighten
two bolts.
3. Plug the DLC cable into the 16 pin data link connector.
4. Turn the ignition switch to the "ON" position (do not start the engine).
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering -
Steering Angle Sensor Centering Procedure
Steering Angle Sensor: Technical Service Bulletins Steering - Steering Angle Sensor Centering
Procedure
Group: CHASSIS
Number: 05-50-003
DESCRIPTION:
All 2006 MY Sonata vehicles are equipped with Electronic Stability Control (ESC). The ESC system
contains a steering angle sensor, which measures the amount and rate of steering wheel input.
The steering angle sensor is used by the ESC to determine if brake or engine torque interventions
should be activated to help the driver.
The steering angle sensor requires calibration whenever the following occurs:
This bulletin provides a procedure to recalibrate the steering angle sensor using the Hi-Scan Pro.
NOTE:
Before starting procedure, make sure vehicle has ESC. Look for button on dash.
1. Vehicle alignment must meet the following requirements before steering angle calibration can be
started.
^ Roll the vehicle forward and backward on a flat level surface prior to calibration.
NOTE:
Leave the ignition key in the "OFF" position before starting the following procedure.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering -
Steering Angle Sensor Centering Procedure > Page 2138
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2. Attach the Data Link Connector (DLC) cable to the Hi-Scan Pro main body and securely tighten
two bolts.
3. Plug the DLC cable into the 16 pin data link connector.
4. Turn the ignition switch to the "ON" position (do not start the engine).
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift
Interlock Switch: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK'
Shift Interlock Switch: Customer Interest A/T - Can't Shift Into/Out Of 'PARK'
Number: 06-40-008-1
Subject: AUTOMATIC TRANSAXLE SHIFT LEVER WILL NOT SHIFT OUT OF PARK
DESCRIPTION:
If the shift lever of a 2006 Sonata, Azera or 2007 Santa Fe, Elantra or Entourage vehicle does not
shift into or out of Park, please follow the repair procedure:
REPAIR PROCEDURE:
^ Vehicle
^ "Automatic Transaxle",
^ "Current Data"
^ Brake Switch"
2. Confirm the "Brake Switch" reads "ON" when the brake pedal is depressed. If not, check the
brake switch clearance according to the related shop manual. If the clearance is within
specification, install a known-good brake switch:
^ Check fuses and related wiring as shown in the related E/M, page 5D452-2.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift
Interlock Switch: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 2153
Remove
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-'IT'H P - E ' I ‘ L C C K
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2006 - SONATA
^ Refer to the 2006 or 2007 Sonata Shop Manual, page BD-52 and remove the center panel.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
2006 - AZERA:
^ Refer to the 2006 or 2007 Azera Shop Manual, page BD-62 and remove the glove box.
^ Remove the two nuts and disconnect the M76 connector to the ATM key lock control module. Go
to "Test Procedure".
2007 - ENTOURAGE:
^ Refer to the 2007 Entourage Shop Manual, page BD-61 and remove the floor console cover.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift
Interlock Switch: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 2154
2007 - SANTA FE:
^ Refer to the 2007 Santa Fe Shop Manual, page BD-63 and remove the center fascia panel.
^ Disconnect the M02 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Santa Fe ETM, page CL- 11, photo 61 for clarity).
2007 - ELANTRA
^ Refer to the 2007 Elantra Shop Manual, page BD-51 and remove the lower panel.
^ Disconnect the M12 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Elantra ETM, page CL-7, photo 38 for clarity).
TEST PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Interest for Shift
Interlock Switch: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 2155
EflflTH ELANTRA
Ftaplau-a ATM
n- 9535!]-
Qfiflfifl-
EI-lflflfl
“NEH
W34: Innparafiva
"U15; PIEHJI' ml'llflEf-l E: Eil'flLfl'L flpfll'l Eir'Guil
3. Turn the ignition switch to the "ON" position. Check voltage at the pins according to table. If the
voltages are correct, replace the ATM key lock control module.
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Switch: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK'
Shift Interlock Switch: All Technical Service Bulletins A/T - Can't Shift Into/Out Of 'PARK'
Number: 06-40-008-1
Subject: AUTOMATIC TRANSAXLE SHIFT LEVER WILL NOT SHIFT OUT OF PARK
DESCRIPTION:
If the shift lever of a 2006 Sonata, Azera or 2007 Santa Fe, Elantra or Entourage vehicle does not
shift into or out of Park, please follow the repair procedure:
REPAIR PROCEDURE:
^ Vehicle
^ "Automatic Transaxle",
^ "Current Data"
^ Brake Switch"
2. Confirm the "Brake Switch" reads "ON" when the brake pedal is depressed. If not, check the
brake switch clearance according to the related shop manual. If the clearance is within
specification, install a known-good brake switch:
^ Check fuses and related wiring as shown in the related E/M, page 5D452-2.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Switch: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 2161
Remove
nuts
HIM H'HLEVII
Emir." _
-'IT'H P - E ' I ‘ L C C K
- ':- mmmr
2006 - SONATA
^ Refer to the 2006 or 2007 Sonata Shop Manual, page BD-52 and remove the center panel.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
2006 - AZERA:
^ Refer to the 2006 or 2007 Azera Shop Manual, page BD-62 and remove the glove box.
^ Remove the two nuts and disconnect the M76 connector to the ATM key lock control module. Go
to "Test Procedure".
2007 - ENTOURAGE:
^ Refer to the 2007 Entourage Shop Manual, page BD-61 and remove the floor console cover.
^ Disconnect the M01 connector to the ATM key lock control module. Go to "Test Procedure".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Switch: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 2162
2007 - SANTA FE:
^ Refer to the 2007 Santa Fe Shop Manual, page BD-63 and remove the center fascia panel.
^ Disconnect the M02 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Santa Fe ETM, page CL- 11, photo 61 for clarity).
2007 - ELANTRA
^ Refer to the 2007 Elantra Shop Manual, page BD-51 and remove the lower panel.
^ Disconnect the M12 connector to the ATM key lock control module. Go to "Test Procedure".
(Refer to the 2007 Elantra ETM, page CL-7, photo 38 for clarity).
TEST PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Shift Interlock Switch: > 06-40-008-1 > Oct > 06 > A/T - Can't Shift Into/Out Of 'PARK' > Page 2163
EflflTH ELANTRA
Ftaplau-a ATM
n- 9535!]-
Qfiflfifl-
EI-lflflfl
“NEH
W34: Innparafiva
"U15; PIEHJI' ml'llflEf-l E: Eil'flLfl'L flpfll'l Eir'Guil
3. Turn the ignition switch to the "ON" position. Check voltage at the pins according to table. If the
voltages are correct, replace the ATM key lock control module.
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Locations
PHOTEHB
"I“?!
%%I% cIéti‘HJr- V
{ k l - I I 'I-I
, ' I Air-333nm}- ’
II_.;.. -IE| Inn-II! d I ,
‘II E15I1.'ILL.E1IH31}
'I.HI"I'SE IEEIEHflTDH ”B
flu-"I
“I 1'"- 11:11.5
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Mode Switch: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode'
Transmission Mode Switch: Customer Interest A/T - Won't Shift In 'D', Shifts in 'Sports Mode'
Group: TRANSAXLE
Number: 06-40-013
Model: 2001 ~ SANTA FE & XG, 2002 ~ SONATA, 2003 ~ TIBURON, 2005 ~ TUCSON, 2006 ~
AZERA
DESCRIPTION:
If you are servicing a vehicle equipped with a "SHIFTRONIC(TM)" automatic transaxle that has the
following symptoms, refer to the repair procedure shown below:
^ Will not shift in "D" position, but shifts correctly in "Sports Mode"
TEST PROCEDURE:
A 2 I [I LEVEL, FiLI.
11H :TIHTEI-l
u'f WITH-l
'l' Ulfll' 311 "III
--n|'-;r_ m u m
”HI-1"? ”11!l III" 31-F—
..| j' Ih|:i| 1rlliu'H "Ll
Sports Mada
Select Switch
- "an SUITE“
'I ::.I.||III-.Il
-I Lr'l‘I-f 'El-III'IEII
- . " . E EHI‘IEH
-. HI-lF |I '-
With ignition key "ON" and engine off, select "Sports Mode Select Switch."
Check the operation of the select switch when the shift lever is moved from "D" to "Sports Mode"
and back.
Select:
^ F2, "SCRN" two times (this will isolate top two data to provide a quick refresh rate)
Shift the Sports Mode lever to the upshift and downshift positions and check the operation of the
switches:
SWITCH BOX REPLACEMENT (2001~SANTA FE & XG, 2002 SONATA & 2003 TIBURON):
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Mode Switch: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' > Page
2176
If the switches do not operate as shown above, proceed as follows:
1. Refer to the appropriate shop manual, "Body" section and remove the center console.
2. Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
3. Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and
replace the switch box assembly.
GEAR SHIFT LEVER REPLACEMENT (2006 SONATA & AZERA, 2007 SANTA FE):
^ Refer to the appropriate shop manual, 'Body" section, to remove the center console.
^ Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
^ Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and replace
the gear shift lever assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Mode Switch: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' > Page
2177
PART NAME
Eflflfln-flfi Ennata
Eflfl1~flfl Santa Fe
Eflfl1~fl5 IGBflDflfifl Smith bu: Easy
EBD3~ T||:Iurun 4ET4D-2U1Dfl
2flflfi~ Tumun #E?ED—2Eflflfl
EQUEH Eunata
46H [II-3 Hflflfl
Eflflfi~ Azera
Gan" shift lava
EflD?~ Ea ntEI FE 4ET1U-EE1UU
EWHE Sunata
2m1-flfl Santa Fe 45?4fl-39I‘.|flfl
2M1-fl5 mammal:
NEE G31
45T4D-2G1DID
fiTflfl-EEHI}
4ET1fl-3Hfl'flfl
PARTS INFORMATION:
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Mode Switch: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode'
Transmission Mode Switch: All Technical Service Bulletins A/T - Won't Shift In 'D', Shifts in 'Sports
Mode'
Group: TRANSAXLE
Number: 06-40-013
Model: 2001 ~ SANTA FE & XG, 2002 ~ SONATA, 2003 ~ TIBURON, 2005 ~ TUCSON, 2006 ~
AZERA
DESCRIPTION:
If you are servicing a vehicle equipped with a "SHIFTRONIC(TM)" automatic transaxle that has the
following symptoms, refer to the repair procedure shown below:
^ Will not shift in "D" position, but shifts correctly in "Sports Mode"
TEST PROCEDURE:
A 2 I [I LEVEL, FiLI.
11H :TIHTEI-l
u'f WITH-l
'l' Ulfll' 311 "III
--n|'-;r_ m u m
”HI-1"? ”11!l III" 31-F—
..| j' Ih|:i| 1rlliu'H "Ll
Sports Mada
Select Switch
- "an SUITE“
'I ::.I.||III-.Il
-I Lr'l‘I-f 'El-III'IEII
- . " . E EHI‘IEH
-. HI-lF |I '-
With ignition key "ON" and engine off, select "Sports Mode Select Switch."
Check the operation of the select switch when the shift lever is moved from "D" to "Sports Mode"
and back.
Select:
^ F2, "SCRN" two times (this will isolate top two data to provide a quick refresh rate)
Shift the Sports Mode lever to the upshift and downshift positions and check the operation of the
switches:
SWITCH BOX REPLACEMENT (2001~SANTA FE & XG, 2002 SONATA & 2003 TIBURON):
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Mode Switch: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' >
Page 2184
If the switches do not operate as shown above, proceed as follows:
1. Refer to the appropriate shop manual, "Body" section and remove the center console.
2. Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
3. Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and
replace the switch box assembly.
GEAR SHIFT LEVER REPLACEMENT (2006 SONATA & AZERA, 2007 SANTA FE):
^ Refer to the appropriate shop manual, 'Body" section, to remove the center console.
^ Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
^ Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and replace
the gear shift lever assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Mode Switch: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' >
Page 2185
PART NAME
Eflflfln-flfi Ennata
Eflfl1~flfl Santa Fe
Eflfl1~fl5 IGBflDflfifl Smith bu: Easy
EBD3~ T||:Iurun 4ET4D-2U1Dfl
2flflfi~ Tumun #E?ED—2Eflflfl
EQUEH Eunata
46H [II-3 Hflflfl
Eflflfi~ Azera
Gan" shift lava
EflD?~ Ea ntEI FE 4ET1U-EE1UU
EWHE Sunata
2m1-flfl Santa Fe 45?4fl-39I‘.|flfl
2M1-fl5 mammal:
NEE G31
45T4D-2G1DID
fiTflfl-EEHI}
4ET1fl-3Hfl'flfl
PARTS INFORMATION:
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 2186
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N
Group TRANSAXLE
Number 09-AT-013
This TSB supersedes TSB 03-40-013 to add repair information (Steps 2-3).
DESCRIPTION:
An improperly adjusted or improperly operating range switch may result in the following conditions:
This TSB provides information concerning the proper adjustment and diagnosis of the transaxle
range switch.
PARTS INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 2195
MODEL OPERA“ MATURE
TIME CODE cane
IDDFDB Elantm Sudan
1BBE~D5 Sunni-a
Ill
2m3~ lumn
“5
2m1~ [15 JILGEDD
EDDE~ Accent
2306*- Mara 4270mm C15
BEEF- Elantra Sedan
2DDE~ Elantra Taming
[LB
EDDF Entuuragu
2m1~ Santa Fa
20W- Sunata
EDGE- Tumn
All EDS
m m I13
umfinn
a t pillar
EMF
WARRANTY INFORMATION
Service Procedure
1. Attach a GDS and check for DTC in both the "Engine" and "Automatic Transaxle" menus. Go to
Step 2 for 2000-02 Accent or Step 3 for 2006-Sonata. For other vehicles, go to Step 4.
a. Check the rear combination lamp ground bolts for tightness and good electrical contact (refer to
applicable ETM, "Tail, Parking & License Lamps" section). Go to Step b.
b. For 2006-Sonata: Remove the center console cover and check for contamination on the M40
connector to the sports mode switch. If so, clean and repair the connector as necessary. Go to step
c below.
c. For 2006-07 Sonata: Remove the front pillar cover and verify the harness is properly routed near
the clip. Repair the harness as necessary. Go to Step 4.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 2196
SHIFI' LEVER 603
P PIN
R R
N PIN
D D
4. Attach a GDS and select vehicle, "A/T" menu, "Current Data" and "Shift Lever Switch".
5. Move the shift lever and confirm the GDS reads the gear shift position as shown above. If so, the
harness currently does not have an open or short circuit between. the PCM/TCM and range switch.
7. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If so, go to Step 8
^ If not, go to Step 11
8. Inspect the connector to the range switch for a bent pin or pin not fully inserted and related
wiring for an open or short circuit. If OK, follow the repair procedure below:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 2197
Insert M5 um: I
10. Attach the lever and nut. Tighten the nut to specification. Go to Step 11.
13. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification. Remove the 5mm drill or M5 bolt.
14. Move the shift lever to the "N" position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
16. Drive the vehicle two key-on to key-off drive cycles, including shifting to gears D, 3, 2, L (if
equipped) and R. If the:
^ DTC resets, repair or replace the control harness. If the DTC sets again, replace the TCM.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode'
Transmission Position Switch/Sensor: Customer Interest A/T - Won't Shift In 'D', Shifts in 'Sports
Mode'
Group: TRANSAXLE
Number: 06-40-013
Model: 2001 ~ SANTA FE & XG, 2002 ~ SONATA, 2003 ~ TIBURON, 2005 ~ TUCSON, 2006 ~
AZERA
DESCRIPTION:
If you are servicing a vehicle equipped with a "SHIFTRONIC(TM)" automatic transaxle that has the
following symptoms, refer to the repair procedure shown below:
^ Will not shift in "D" position, but shifts correctly in "Sports Mode"
TEST PROCEDURE:
A 2 I [I LEVEL, FiLI.
11H :TIHTEI-l
u'f WITH-l
'l' Ulfll' 311 "III
--n|'-;r_ m u m
”HI-1"? ”11!l III" 31-F—
..| j' Ih|:i| 1rlliu'H "Ll
Sports Mada
Select Switch
- "an SUITE“
'I ::.I.||III-.Il
-I Lr'l‘I-f 'El-III'IEII
- . " . E EHI‘IEH
-. HI-lF |I '-
With ignition key "ON" and engine off, select "Sports Mode Select Switch."
Check the operation of the select switch when the shift lever is moved from "D" to "Sports Mode"
and back.
Select:
^ F2, "SCRN" two times (this will isolate top two data to provide a quick refresh rate)
Shift the Sports Mode lever to the upshift and downshift positions and check the operation of the
switches:
SWITCH BOX REPLACEMENT (2001~SANTA FE & XG, 2002 SONATA & 2003 TIBURON):
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' > Page 2204
If the switches do not operate as shown above, proceed as follows:
1. Refer to the appropriate shop manual, "Body" section and remove the center console.
2. Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
3. Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and
replace the switch box assembly.
GEAR SHIFT LEVER REPLACEMENT (2006 SONATA & AZERA, 2007 SANTA FE):
^ Refer to the appropriate shop manual, 'Body" section, to remove the center console.
^ Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
^ Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and replace
the gear shift lever assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' > Page 2205
PART NAME
Eflflfln-flfi Ennata
Eflfl1~flfl Santa Fe
Eflfl1~fl5 IGBflDflfifl Smith bum Easy
Eflfl'fl'” ‘I'Ihurun 4ET4D-2U1U'I}
EWHE Sunata
2m1-flfl Santa Fe
2M1-fl5 mammal: 4E?4flRDfl Switch hm:
as”
20-05" Surflta
2W6- Aza'a
PARTS INFORMATION:
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE'
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DIG are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
m
h
E
5
I
m
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
LE BflLlHflID BUT!
[III HELENE!!! BUT!
EHD BELEHIIIII DUI!
02D BflLlHflIll BUT!
BED EDLEHHID DUI!
flIL IMPEBHIUEE
SHIFT POEITIDH
8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 2212
1. 2 CURRENT IH-‘I‘I'FI
l H H H - H ‘ H
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^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 2213
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
Group TRANSAXLE
Number 09-AT-013
This TSB supersedes TSB 03-40-013 to add repair information (Steps 2-3).
DESCRIPTION:
An improperly adjusted or improperly operating range switch may result in the following conditions:
This TSB provides information concerning the proper adjustment and diagnosis of the transaxle
range switch.
PARTS INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's
P0705/P0707/P0708/No Start In P/N > Page 2219
MODEL OPERA“ MATURE
TIME CODE cane
IDDFDB Elantm Sudan
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EDGE- Tumn
All EDS
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EMF
WARRANTY INFORMATION
Service Procedure
1. Attach a GDS and check for DTC in both the "Engine" and "Automatic Transaxle" menus. Go to
Step 2 for 2000-02 Accent or Step 3 for 2006-Sonata. For other vehicles, go to Step 4.
a. Check the rear combination lamp ground bolts for tightness and good electrical contact (refer to
applicable ETM, "Tail, Parking & License Lamps" section). Go to Step b.
b. For 2006-Sonata: Remove the center console cover and check for contamination on the M40
connector to the sports mode switch. If so, clean and repair the connector as necessary. Go to step
c below.
c. For 2006-07 Sonata: Remove the front pillar cover and verify the harness is properly routed near
the clip. Repair the harness as necessary. Go to Step 4.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's
P0705/P0707/P0708/No Start In P/N > Page 2220
SHIFI' LEVER 603
P PIN
R R
N PIN
D D
4. Attach a GDS and select vehicle, "A/T" menu, "Current Data" and "Shift Lever Switch".
5. Move the shift lever and confirm the GDS reads the gear shift position as shown above. If so, the
harness currently does not have an open or short circuit between. the PCM/TCM and range switch.
7. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If so, go to Step 8
^ If not, go to Step 11
8. Inspect the connector to the range switch for a bent pin or pin not fully inserted and related
wiring for an open or short circuit. If OK, follow the repair procedure below:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's
P0705/P0707/P0708/No Start In P/N > Page 2221
Insert M5 um: I
10. Attach the lever and nut. Tighten the nut to specification. Go to Step 11.
13. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification. Remove the 5mm drill or M5 bolt.
14. Move the shift lever to the "N" position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
16. Drive the vehicle two key-on to key-off drive cycles, including shifting to gears D, 3, 2, L (if
equipped) and R. If the:
^ DTC resets, repair or replace the control harness. If the DTC sets again, replace the TCM.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1720307-02 > Mar > 07 > A/T Controls - Neutral
Position Switch Adaptive Relearn
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Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - Neutral
Position Switch Adaptive Relearn
Resetting Adaptive Learning and Range Switch Neutral Position Learning
If the transaxle or transaxle control unit is replaced, the TCU adaptive learning values must be
reset (erased) and the range switch neutral position must be relearned using either the GDS or
Hi-Scan Pro. If the following procedures are not completed, the following conditions may occur:
^ Stop the vehicle, move the shift lever to "P" and set the parking brake.
Follow the instructions on the screen and confirm the test indicates "Completed:"
Luci-5.9m nut
^ Stop the vehicle, move the shift lever to "N" and set the parking brake.
^ Loosen the nut on the shift cable. Align the dot (o) on the shift lever to the "N" mark on the TCU.
— ' — I _ I
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^ Follow the instructions on the screen and confirm the test indicates "Completed."
^ Move the shift lever from "P" to "D" and confirm the shift position indicator on the dash reads
correctly. Confirm the correct gear indication using the Hi-Scan or GDS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D',
Shifts in 'Sports Mode'
Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Won't Shift In 'D', Shifts
in 'Sports Mode'
Group: TRANSAXLE
Number: 06-40-013
Model: 2001 ~ SANTA FE & XG, 2002 ~ SONATA, 2003 ~ TIBURON, 2005 ~ TUCSON, 2006 ~
AZERA
DESCRIPTION:
If you are servicing a vehicle equipped with a "SHIFTRONIC(TM)" automatic transaxle that has the
following symptoms, refer to the repair procedure shown below:
^ Will not shift in "D" position, but shifts correctly in "Sports Mode"
TEST PROCEDURE:
A 2 I [I LEVEL, FiLI.
11H :TIHTEI-l
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--n|'-;r_ m u m
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Sports Mada
Select Switch
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With ignition key "ON" and engine off, select "Sports Mode Select Switch."
Check the operation of the select switch when the shift lever is moved from "D" to "Sports Mode"
and back.
Select:
^ F2, "SCRN" two times (this will isolate top two data to provide a quick refresh rate)
Shift the Sports Mode lever to the upshift and downshift positions and check the operation of the
switches:
SWITCH BOX REPLACEMENT (2001~SANTA FE & XG, 2002 SONATA & 2003 TIBURON):
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D',
Shifts in 'Sports Mode' > Page 2234
If the switches do not operate as shown above, proceed as follows:
1. Refer to the appropriate shop manual, "Body" section and remove the center console.
2. Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
3. Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and
replace the switch box assembly.
GEAR SHIFT LEVER REPLACEMENT (2006 SONATA & AZERA, 2007 SANTA FE):
^ Refer to the appropriate shop manual, 'Body" section, to remove the center console.
^ Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
^ Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and replace
the gear shift lever assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D',
Shifts in 'Sports Mode' > Page 2235
PART NAME
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2m1-flfl Santa Fe 45?4fl-39I‘.|flfl
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fiTflfl-EEHI}
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PARTS INFORMATION:
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov > 05 > A/T - No Movement In
Drive/Reverse
MODEL: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DTC in both the "Engine" and "Automatic Transaxle" menus:
^ If DTC are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to Step 9
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov > 05 > A/T - No Movement In
Drive/Reverse > Page 2240
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
shift cable to the lever and install the nut. Tighten the nut to specification.
. I ‘
“‘-
‘ "I'-
- ' fi .
__"-'I
"-1-.
H
l I!
Wu: I l m m l l m l l m l l m l l m fl
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov > 05 > A/T - No Movement In
Drive/Reverse > Page 2242
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
12. Install the A/T Tester, P/N 09450-AT000, to the vehicle:
^ Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottompan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an
^ If no problem is found swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse
WARRANTY INFORMATION:
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
m
h
E
5
I
m
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
LE BflLlHflID BUT!
[III HELENE!!! BUT!
EHD BELEHIIIII DUI!
02D BflLlHflIll BUT!
BED EDLEHHID DUI!
flIL IMPEBHIUEE
SHIFT POEITIDH
8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-40-016 > Oct > 05 > A/T - No Movement in
'DRIVE' or 'REVERSE' > Page 2249
1. 2 CURRENT IH-‘I‘I'FI
l H H H - H ‘ H
an EDIE”!!! Ell"!
fllL I w m m
'1
SHIFT PflSITIfl'I
"5'1 T: T.. T'I1'Z T L Flt-T F: FH-J.
l-‘IH I - I m l m l m l m -
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-40-016 > Oct > 05 > A/T - No Movement in
'DRIVE' or 'REVERSE' > Page 2250
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
1-
1m
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E {- .l Uhrllrfll-
i'r-J-‘Hur
lmnmmml
J huh— mile-I..-
“ m l h fl fl h fl l fl fl fl
“ H I - fl “ !
“ a n
Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - Neutral
Position Switch Adaptive Relearn
Resetting Adaptive Learning and Range Switch Neutral Position Learning
If the transaxle or transaxle control unit is replaced, the TCU adaptive learning values must be
reset (erased) and the range switch neutral position must be relearned using either the GDS or
Hi-Scan Pro. If the following procedures are not completed, the following conditions may occur:
^ Stop the vehicle, move the shift lever to "P" and set the parking brake.
Follow the instructions on the screen and confirm the test indicates "Completed:"
Luci-5.9m nut
^ Stop the vehicle, move the shift lever to "N" and set the parking brake.
^ Loosen the nut on the shift cable. Align the dot (o) on the shift lever to the "N" mark on the TCU.
— ' — I _ I
-_-—-_I.I—H.l—.-—.In.—h-.
" - - - _ - ‘ . — i '
ll - . .- --'—:
‘1 ill. l — — *
i i |-I-'I-|I
II—I-IIII-il-
I--IIfl"'1II-ln Ir_-|-I-I.
- - - -
E. a nm
II. I'll“I “ .
H. m m ! 'l‘fll'
I5. alarm
5 . FREE! PET-I'll HII'FI
IT. FIGHTING fll'l'fl I'd"! m
^ Follow the instructions on the screen and confirm the test indicates "Completed."
^ Move the shift lever from "P" to "D" and confirm the shift position indicator on the dash reads
correctly. Confirm the correct gear indication using the Hi-Scan or GDS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov > 05 > A/T - No Movement In
Drive/Reverse
MODEL: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DTC in both the "Engine" and "Automatic Transaxle" menus:
^ If DTC are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to Step 9
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov > 05 > A/T - No Movement In
Drive/Reverse > Page 2262
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
shift cable to the lever and install the nut. Tighten the nut to specification.
. I ‘
“‘-
‘ "I'-
- ' fi .
__"-'I
"-1-.
H
l I!
Wu: I l m m l l m l l m l l m l l m fl
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov > 05 > A/T - No Movement In
Drive/Reverse > Page 2264
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
12. Install the A/T Tester, P/N 09450-AT000, to the vehicle:
^ Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottompan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an
^ If no problem is found swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse
WARRANTY INFORMATION:
Transmission Speed Sensor: Customer Interest A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh
Engagement
Group TRANSAXLE
Number 09-AT-016
DESCRIPTION:
NOTE:
This TSB updates TSB 07-40-016 to add repair information (Step 6).
An improperly functioning input speed sensor or output speed sensor may result in the following
conditions:
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IMT— EHTDURAGE 3.8L EUGE- AEERA 3.3L 8‘. 3.3L
PARTS INFORMATION
SERVICE PROCEDURE:
1. Using a GDS, check for DTCs in both the "Engine" and "Automatic Transaxle" menus. Record
the DTC and description.
^ Vehicle
^ "Input speed sensor" and "output speed sensor". Drive the vehicle and monitor the input and
output speed sensors. If the sensors show:
^ No output, go to Step 3
3. Check the wiring harness visually for an open circuit or short circuit to ground. Check for a
pinched harness at the PCM/TCM attachment bolts.
4. Disconnect the connectors at the input and output speed sensor and PCM/TCM. Check for bent
pins or pins not fully inserted into the connector.
5. If a harness open/short is found, repair or replace the ECM control harness between the
PCM/TCM and transaxle and go to Step 8. If not, go to Step 6.
6. P0722 ONLY: For 2006~ Sonata, 2007~ Santa Fe, 2007~ Entourage and 2006~ Azera vehicles,
check the ground bolt at the location shown. Confirm the threads are clean and the bolt is tight.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 09-AT-016 > Aug > 09 > A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh
Engagement > Page 2274
7. If the ground bolts are clean and tight, follow the repair procedure shown above.
8. Drive the vehicle for two key-on to key-off driving cycles. If the codes:
9. Exchange a PCM or TCM from a similar year and model vehicle (excluding vehicles with
immobilizer). If the codes:
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 09-AT-016 > Aug > 09 > A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh
Engagement
Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL ON/DTC's Set/Fail Safe
Mode/Harsh Engagement
Group TRANSAXLE
Number 09-AT-016
DESCRIPTION:
NOTE:
This TSB updates TSB 07-40-016 to add repair information (Step 6).
An improperly functioning input speed sensor or output speed sensor may result in the following
conditions:
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17'
|_G14
IMT— EHTDURAGE 3.8L EUGE- AEERA 3.3L 8‘. 3.3L
PARTS INFORMATION
SERVICE PROCEDURE:
1. Using a GDS, check for DTCs in both the "Engine" and "Automatic Transaxle" menus. Record
the DTC and description.
^ Vehicle
^ "Input speed sensor" and "output speed sensor". Drive the vehicle and monitor the input and
output speed sensors. If the sensors show:
^ No output, go to Step 3
3. Check the wiring harness visually for an open circuit or short circuit to ground. Check for a
pinched harness at the PCM/TCM attachment bolts.
4. Disconnect the connectors at the input and output speed sensor and PCM/TCM. Check for bent
pins or pins not fully inserted into the connector.
5. If a harness open/short is found, repair or replace the ECM control harness between the
PCM/TCM and transaxle and go to Step 8. If not, go to Step 6.
6. P0722 ONLY: For 2006~ Sonata, 2007~ Santa Fe, 2007~ Entourage and 2006~ Azera vehicles,
check the ground bolt at the location shown. Confirm the threads are clean and the bolt is tight.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 09-AT-016 > Aug > 09 > A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh
Engagement > Page 2281
7. If the ground bolts are clean and tight, follow the repair procedure shown above.
8. Drive the vehicle for two key-on to key-off driving cycles. If the codes:
9. Exchange a PCM or TCM from a similar year and model vehicle (excluding vehicles with
immobilizer). If the codes:
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass
Element Switch > Component Information > Testing and Inspection > Rear Window Defogger Switch
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INSPECTION
2. Remove the center facia panel (A) by using a scraper (B). Take care of fixing clip. 3. Disconnect
the connectors.
4. Using an ohmmeter, inspection the continuity between the terminals after removing to the switch
connector.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass
Element Switch > Component Information > Testing and Inspection > Rear Window Defogger Switch > Page 2287
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INSPECTION
2. Remove the center facia panel(A) by using a scraper (B). Take care of fixing clip. 3. Disconnect
the connectors.
4. Using an ohmmeter, inspection the continuity between the terminals after removing to the switch
connector.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Component Locations
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Locations > Component Locations > Page 2292
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Power Window Switch: Connector Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions
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Power Window Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2295
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2298
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2299
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2300
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2301
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2303
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2304
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2305
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2306
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2307
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2308
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2309
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2310
CIRCUIT DIAGRAM m
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Circuit Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2311
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2312
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For information regarding diagrams for this component, please refer to Windows diagrams. See:
Windows and Glass/Windows/Diagrams/Electrical Diagrams
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Page 2313
Power Window Switch: Testing and Inspection
INSPECTION
1. Disconnect the negative (-) battery terminal. 2. Remove the front door trim panel.
4. Check for continuity between the terminals in each switch position according to the table. If the
continuity condition is not normal, replace the
switch.
1. Disconnect the negative (-) battery terminal. 2. Remove the front door trim panel.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window
Switch > Component Information > Diagrams > Page 2314
3. Disconnect the 11p connector from the switch.
4. Check for continuity between the terminals in each switch position according to the table. If the
continuity condition is not normal, replace the
switch.
1. Disconnect the negative (-) battery terminal. 2. Remove the rear door trim panel.
switch.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Testing and Inspection
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Wiper Switch: Testing and Inspection
INSPECTION
Check for continuity between the terminals while operating the wiper and washer switch. if it is not
normal condition, replace wiper and wiper switch.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Testing and Inspection > Page 2323
REPLACEMENT
1. Remove the steering column upper and lower shrouds (A) after removing 3 screws.
2. Remove the wiper switch (A) by pushing the lock pin (B) after disconnecting the connector. 3.
Installation is the reverse of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Drift/Pull Diagnosis/Repair
Alignment: Technical Service Bulletins Steering/Suspension - Drift/Pull Diagnosis/Repair
Number: 08-SS-004
Model: ALL
DESCRIPTION:
Several factors may cause vehicle pull, both vehicle related and external conditions. The purpose
of this bulletin is to assist in identifying the vehicle related conditions that cause pull and how to
correct those conditions.
Vehicle pull is the tendency of the vehicle to drift right or left while driving in a straight ahead
direction on a straight road at a constant speed with no pressure on the steering wheel. This pull or
drift may be gradual and can always be compensated for by inputs through the steering wheel. One
or more of the following conditions may cause the vehicle to pull:
Cambered road surfaces - Most highways are built with cambered or "crowned" surfaces to drain
rain water. Sometimes the road camber is visually noticeable. Other times, it is not. The vehicle
may tend to pull to the left or right, depending on the camber of the road surface.
Cross-winds - A sometimes overlooked, yet possible cause of steering drift is cross-winds. Side
winds at higher vehicle speeds may cause vehicle pull. Please do not rule out cross-winds when
diagnosing a vehicle pull.
Vehicle pull caused by these two conditions is not related to vehicle adjustments and no repair
should be made.
Tire inflation pressure - As small as a 2 pounds/square inch tire inflation pressure difference
between the right and left tires may cause a vehicle to pull. Be sure to check the tire pressure
before the tires are warmed up prior to attempting more extensive diagnosis.
Wheel alignment - Slightly out of specification wheel alignment causes very few vehicles to pull.
Therefore, if the vehicle wheel alignment has been adjusted as close as possible to specification,
DO NOT attempt to correct the vehicle pull by changing the wheel alignment angles by bending
suspension components or other non-approved methods.
Uneven brake adjustment - If one of the four brakes is dragging, the vehicle may pull to the side of
the dragging brake. Verify that none of the brakes are dragging and that they are adjusted correctly
prior to attempting more extensive diagnosis.
^
Incorrect vehicle trim height - If the trim height of the vehicle is not equal on all sides, the vehicle
may pull to the side of the lower trim height. Check and adjust the trim height of the vehicle as
necessary. Please note that a slight variation in the vehicle trim height seldom causes a noticeable
vehicle pull.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Drift/Pull Diagnosis/Repair > Page 2329
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^ Tire construction - The way in which the tire is built can produce vehicle pull. An example of this
is the placement of the under tread belt. An off-center radial tire belt can cause the tire to develop a
side force while rolling straight down the road and the tire will tend to roll like a cone. To correct this
condition, please use the flow chart. This chart provides the sequence of procedures designed to
be performed for all conditions of vehicle pull.
^ Tire size - Different size tires or different make of tires, on either axles, may cause a vehicle pull.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Drift/Pull Diagnosis/Repair > Page 2330
Incunt-ct purl-rim“ at the In: rad Rulilu In: rod and T" ”I “lull!” im“!
Group: CHASSIS
Number: 06-50-017
DESCRIPTION:
This bulletin describes the correct position of the tie rod end for Azera (TC) and Sonata (NF)
vehicles.
During toe-in adjustment, the tie rod end (B) may move towards the stabilizer bar link (A) and
reduce the clearance between the two parts as shown.
After toe-in adjustment, tighten the tie rod end lock nuts firmly then rotate the tie rod end with a
wrench to increase clearance as shown.
NOTE:
Minimum clearance between the tie rod and the stabilizer bar link may cause an interference noise
when the steering is turned fully or the vehicle is driven over uneven or rough road surfaces.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Drift/Pull Diagnosis/Repair > Page 2331
# # —
Group: CHASSIS
Number: 06-50-004
DESCRIPTION:
The table below lists the 2006 model year vehicle wheel alignment specifications
in Rudy I
Tue-in mrnlin] 3i?!“ flTflTtflflTflfl
Alignment Specifications
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
E H m
“ —
W “Hashim
Negative H tuna [tat-a nut}
WHEEL ALIGNMENT
When using commercially available computerized four wheel alignment equipment (caster, camber,
toe) to inspect the front wheel alignment, always position the car on a level surface with the front
wheels facing straight ahead. Prior to inspection, make sure that the front suspension and steering
system are in normal operating condition and that the wheels and tires face straight ahead and the
tires are inflated to the specified pressure.
TOE
Toe is a measurement of how much the front of the wheels are turned in or out from the
straight-ahead position. When the wheels are turned in toward the front of the vehicle, toe is
positive (+) (toe inch). When the wheels are turned out toward the front of the vehicle, toe is
negative (-) (toe out). Toe is measured in degrees, from side to side, and totaled.
[FRONT]
Toe-in (B-A or angle a+b) is adjusted by turning the tie rod turnbuckles. Toe-in on the left front
wheel can be reduced by turning the tie rod toward the rear of the car. Toe- in change is adjusted
by turning the tie rods for the right and left heels simultaneously at the same amount as follows.
NOTE: Toe-in adjustment should be made by turning the right and left tie rods at the same amount
When adjusting toe-in, loosen the outer bellows clip to prevent twisting the bellows. After the
adjustment, tighten the tie rod end lock nuts firmly and reinstall the bellows clip. Adjust each toe-in
to be the range of ± 1 mm.
Tie rod (A) Specified torque: 50 - 55 Nm (5 - 5.5 kgf-cm, 36.2 - 39.8 ft. lbs.)
[REAR]
Standard value Toe-in (B-A) mm (in): 2 ± 2 (0.0787 ± 0.0787) Adjust the toe-in by turning the cam
bolt of the assist arm.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment >
Page 2335
Left cam bolt: Clockwise - toe-in Right cam bolt: Clockwise - toe-out The variation of toe by a
rotation of the cam bolt About 4.1 mm (0.4)
CAUTION: Each toe should be within 1 ± 1 mm (0.039 0.039 inch). If the difference between right
and left is not within +2 mm (0.079 inch), repeat adjustment After adjusting the cam bolt, tighten the
nut to the specified torque.
Specified torque 110 - 120 Nm (11 - 12 kgf-m 79.5 - 86.8 ft. lbs.)
CAMBER
[FRONT]
Camber is the inward or outward tilting of the wheels at the top. When the wheel tilts out at the top,
then the camber is positive (+). When the wheel tilts in at the top, then the camber is negative (-).
NOTE: Camber is pre-set at the factory and does not need to be adjusted. If the camber is not
within the standard value, replace the bent or damaged parts.
[REAR]
Standard value: -0030' ± 30' Difference between right and left angle is within 00 30'
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment >
Page 2336
[HEAR]
Standard value : HD' :I: 311'
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CASTER
Caster is the tilting of the strut axis either forward or backward from vertical. A backward tilt is
positive (+) and a forward tilt is negative (-).
Caster is pre-set at the factory and doesn't need to be adjusted. If the caster is not within the
standard value, replace the bent or damaged parts.
NOTE: ^
The worn loose or damaged parts of the front suspension assembly must be replaced prior to
measuring front wheel alignment. Camber and caster are pre-set to the specified value at the
factory and don't need to be adjusted.
^ If the camber and caster are not within specifications, replace bent or damaged parts.
^ The difference of left and right wheels about the camber and the caster must be within the range
of 00 ± 30'.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment >
Page 2337
1. Place the front wheel on a turning radius gauge and measure the steering angle.
2. If the measured value is not within the standard value, adjust the toe and inspect again.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Standard
Value:.....................................................................................................................................374 -
384 kPa (3.82 - 3.92 kg/sq.cm, 54.3 - 55.8 psi)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 2342
1. PREPARING
1. Openflteeewieeeeverfl] intrunlt.
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h m m m m w m m m h m m
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fl. INSTALL 11'IE SPEGIAL SERVICE TDD]. [551'] F'D'FI MEASURING TI'IE FUEL FHESSUHE
1. Dleeemeet the fuel teed heee Hunt the dellvenr pipe.
£5 murlm
GetterfltehueeWflmeehupmhpmmlephflmgflmmbymmhflflfimwfl
. Install the Fuel Freeeute Gauge Ampler {MWJretween the dellttery pipe and lhe fuel feed I'Ittee+
. W M F U H Freeeuteaalmcenneeter {05353-2 ltetheFuelFreeeureEetueeeepter [DRESS—W].
. m u t e Fuel Freeeultefiame entl Heee tense-24 [Mlle Fuel Freeman Gauge Getttteetel' m m .
. finnedfltefuel teed heeetettte FuelFreeelt'e GameMeptertflflflfifi-Eflflflfl].
Fuel Plenumlieu:- I Heel [HESS-211nm
Hulfieemmfinnefleflulflflflfifi-Eflflflfl},
- - - ’ _ _
I if the meeeured fuel preaeure differa frern the standard value. perfpnn the neeeaaary repairer
ueing the latte helper.
_ e fuel
gfilter g e d Fuel titer
FLIBI PI'EEEHI'B lull I'DW Fuel leaf: en the fuel-preeeurp
regulater that Ie aeeernbled
ll“ lI-Ifil PUI'HP beeeuee Of peer Fuel Preeeure Ftegulater
mating at the fuel--preeeure
mummif-
5. Step the englne anti llfl'lEElf. fer a ehange in the fuel pmeeure gauge reeding.
After engine etepe. the gauge reading eheultl held fer abeut 5 mlnutee
A
I Dbeenring the deelinatien ef the fuel preeeure when the gauge reading erupe and perlerrn the
neeeeeary repetre uehg the table belew.
EEFEI'EUEIJ
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.mcrs
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”.merefwfispflm.
. Dlsccnnect the Fuel Pressure Gauge and Hess [HESS-241m} frem the Fuel Pressure Gauge Ecnnectcr
['Ilsse-seccc}.
.. Dleccnnect the Fuel Pressure Gauge ficnhectcr {09353-241003} frcm the Fuel Pressure Gauge Adapter
recess-secne}.
. Disccnnect its fuel feed hcse item the Fuel Pressure Gauge Adapter recess-seem}.
. Dlsccnnect the Fuel Pressure Gauge Adapter recess-seem) frem the delivery pipe.
& ceuncu
GsmhMuWflaflwmmmmmmMHmflwmmhffrel'ueillne.
Idle Speed
A/C ON OFF
Natural,N,P-range.................................................................................................................................
.........................................................620 ± 100 rpm D-range...............................................................
.........................................................................................................................................620 ± 100
rpm
A/C ON ON
Natural,N,P-range.................................................................................................................................
.........................................................620 ± 100 rpm D-range...............................................................
...........................................................................................................................................620 ± 100
rpm
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair
1. Disconnect the fuel pump connector(A). 2. Start the engine and wait until fuel in fuel line is
exhausted. 3. After the engine stalls, turn the ignition switch to OFF position and disconnect the
negative (-) terminal from the battery.
NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel feed hose, otherwise fuel
will spill out.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
..............................................................................................................................................................
............................................
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
©®®
Frunt uf 1'ul'rmlnllr';
NOTE: when removing the ignition coil connector, pull the lock pin(A) and push the clip(B).
CAUTION: Be careful that no contaminates enter through the spark plug holes.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection > Page 2362
IHEFEEHUH HF R E M
Fuel mhtm
tun rl'fl'l
Lulu drlnlalu: -
4. Inspect the electrodes (A) and ceramic insulator (B).
NGK .....................................................................................................................................................
.................................................................. IFR5G-11
Gap ......................................................................................................................................................
................................ 1.0-1.1 mm (0.039-0.043 inch)
Torque .................................................................................................................................................
............................................. 20-30 Nm (15-22 lb.ft)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2366
Spark Plug: Application and ID
NGK .....................................................................................................................................................
.................................................................. IFR5G-11
Gap ......................................................................................................................................................
................................ 1.0-1.1 mm (0.039-0.043 inch)
Torque .................................................................................................................................................
............................................. 20-30 Nm (15-22 lb.ft)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2367
Spark Plug: Testing and Inspection
NOTE: when removing the ignition coil connector, pull the lock pin(A) and push the clip(B).
CAUTION: Be careful that no contaminates enter through the spark plug holes.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2368
IHEFEEHUH HF R E M
Fuel mhtm
tun rl'fl'l
Lulu drlnlalu: -
4. Inspect the electrodes (A) and ceramic insulator (B).
ENGINE COMPRESSION
Compression pressure
................................................................................................................................................. 1,283
kPa (13.0 kgf/cm2, 185 psi) Minimum pressure
......................................................................................................................................................
1,135 kPa (1 1.5 kgf/cm2, 164 psi) Difference between each cylinder
............................................................................................................................ 100 kPa (1.0
kgf/cm2, 15 psi) or less
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2372
Compression Check: Testing and Inspection
COMPRESSION
NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking
the engine, measure the compression pressure.
NOTE: Always use a fully charged battery to obtain engine speed of 200 rpm or more.
Compression pressure 1,283 kPa (13.0 kgf/cm2, 185 psi) Minimum pressure: 1,135 kPa (1 1.5
kgf/cm2, 164 psi) Difference between each cylinder 100 kPa (1.0 kgf/cm2, 15 psi) or less
e. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into
the cylinder through the spark plug hole and
repeat steps (a) through (c) for cylinders with low compression. ^
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
^ If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
Intake ...................................................................................................................................................
.................. 0.10 - 0.30 mm (0.0039 - 0.0118 inch) Exhaust ...............................................................
................................................................................................... 0.20 - 0.40 mm (0.0079 - 0.0157
inch)
Specification
Intake ...................................................................................................................................................
................. 0.17 - 0.23 mm (0.0067 - 0.0090 inch) Exhaust ................................................................
.................................................................................................. 0.27 - 0.33 mm (0.0106 - 0.0129
inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 2376
Valve Clearance: Adjustments
NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature: 20°C) and cylinder head is installed on the cylinder block.
1. Remove the engine cover. 2. Remove air cleaner assembly. 3. Remove the surge tank.
a. Disconnect the ignition coil connector and remove the ignition coil. b. Disconnect the breather
hose (A) from the cylinder head cover.
c. Loosen the cylinder head cover bolts and then remove the cover (A) and gasket.
a. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain
cover.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 2377
HH Ex HAUET
a. Check only the valve indicated as shown. [No. 1 cylinder: TDC/Compression] measure the valve
clearance.
- Using a thickness gauge, measure the clearance between the tappet and the base circle of
camshaft.
- Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting tappet.
Valve clearance Specification Engine coolant temperature: 20°C [68°F] Limit Intake: 0.10 - 0.30
mm (0.0039 - 0.0118 inch) Exhaust: 0.20 - 0.40 mm (0.0079 - 0.0157 inch)
b. Turn the crankshaft pulley one revolution (360") and align the groove with timing mark T of the
lower timing chain cover.
a. Set the No. 1 cylinder to the TDC/compression. b. Remove the timing chain. c. Remove the
camshaft bearing caps (A).
g. Calculate the thickness of a new tappet so that the valve clearance comes within the specified
value.
h. Select a new tappet with a thickness as close as possible to the calculated value.
NOTE: Shims are available in 41 size increments of 0.015 mm (0.0006 inch) from 3.00 mm (0.118
inch) to 3.600 mm (0.1417 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 2379
i. Place a new tappet on the cylinder head.
NOTE: Apply engine oil at the selected tappet on the periphery and top surface.
m. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft
sprocket and camshaft sprocket timing marks. n. Recheck the valve clearance.
Valve clearance (Engine coolant temperature: 20°C [68°F]) [Specification] Intake: 0.17 - 0.23 mm
(0.0067 - 0.0090 inch) Exhaust: 0.27 - 0.33 mm (0.0106 - 0.0129 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
LH Timing Chain
RH Timing Chain
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain
at installing timing chain.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams
Crankshaft pulley -> A/C pulley -> idler pulley -> alternator pulley -> water pump pulley -> P/S
pump pulley -> tensioner pulley. Rotate auto tensioner arm in the counter - clockwise moving auto
tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto
tensioner pulley slowly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Description and
Operation
Cabin Air Filter: Description and Operation
DESCRIPTION
This has particle filter which eliminates foreign materials and odor. The particle filter includes odor
filter as well as conventional dust filter to ensure a comfortable interior environment.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Description and
Operation > Page 2392
,JLII
E
I .
Cabin Air Filter: Service and Repair
1. Remove the damper (A) from the glove box after removing the side cover.
2. Open the glove box (A). Lower the glove box down completely by removing the glove box
stopper (B) to the glove box.
3. Remove the filter cover (A) with pushing the knob. 4. replace the air filter (B), install it after
making sure of the direction of the air filter flow.
REPLACE
2. Disconnect the canister close valve wiring connector and the vapor hose to canister (B) 3.
Remove the fuel tank air filter(A). 4. Install a new fuel tank air filter.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
and Repair
1. Disconnect the fuel pump connector(A). 2. Start the engine and wait until fuel in fuel line is
exhausted. 3. After the engine stalls, turn the ignition switch to OFF position and disconnect the
negative (-) terminal from the battery.
NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel feed hose, otherwise fuel
will spill out.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair
Oil Filter: Service and Repair
CAUTION: -
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
- Exercise caution in order to minimize the length and frequency of contact of your skin to used oil.
Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
- In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. Wait for 5 minutes after loosening the oil filter cap by turning it counterclockwise to drain well the
oil in the oil filter. 2. Remove the oil filler cap. 3. Remove the oil drain plug, and drain the oil into a
container.
a. Disconnect the oil filter cap from oil filter body. b. Remove the oil filter element. c. Check and
clean the oil filter installation surface. d. Check the part number of the new oil filter is as same as
old one. e. Install new oil filter element (A) and two O-rings (B). f.
Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat. Tightening
torque 24.50 Nm (2.5 kgf.m, 18.08 ft. lbs.)
a. Clean and install the oil drain plug with a new gasket.
Tightening torque 34.3 - 44.1 Nm (3.5 - 4.5 kgf.m, 25.3 - 32.5 ft. lbs.)
Capacity Drain and refill W/Oil filter change: 5.9 Liters (6.23 U. S. qts, 5.19 Imp. quarts) W/O Oil
filter change: 5.5 Liters (5.81 U. S. qts, 4.84 Imp. quarts) Oil filter: 0.4 Liters (0.42 U.S. qts, 0.35
Imp. quarts)
6. Start engine and check for oil leaks. 7. Recheck engine oil level.
Temperature range
need all d1 belnre
enlleheled Heeem'nemled EAE may umber
NOTE: For best performance and maximum protection of all types of operation, select only those
lubricants which: -
Lubricants that do not have both an SAE grade number and API service classification on the
container should not be used.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair >
Page 2405
22mm Hex, 88mm with 15 Flats Applicable to 2006 Hyundai Sonata, Santa Fe and Azerra (V6)
Made of Aluminum Made in the U.S.A.
Component Location
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Locations > Page
2410
an
n.
.
5”
2
E.
5
3
J
__
quill
I
n.
n.
E.
5
_
mm- EL? -
REPLACEMENT
1. Discharge refrigerant from refrigeration system (Refer to page HA-9). 2. Replace faulty tube or
hose.
CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system.
CAUTION: Connections should not be torque tighter than the specified torque.
4. Evacuate air in refrigeration system and charge system with refrigerant (Refer to page HA-9).
Using a gas leak detector, check for leakage of refrigerant (Refer to page HA-11).
CDHPUHENTB um
COMPONENTS
REMOVAL
While installing the tube and hose assembly, be sure to align white marks on each fitting.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Page 2414
PRESSURE HOSE, TUBE AND RETURN TUBE, HOSE
1. Remove the mounting clamps from the pressure tube and the return tube.
2. Remove the pitting of both the pressure tube and the return tube from the gearbox. 3. Remove
the pressure hose and tube.
INSTALLATION
NOTE: Install the return tube and hoses so that they are not twisted and it does not come in
contact with any other parts. After installation, air bleed
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Page 2415
the system.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins
> Brakes - Brake Fluid Adding/Changing Precautions
Brake Fluid: Technical Service Bulletins Brakes - Brake Fluid Adding/Changing Precautions
Group BRAKES
Number 10-SS-003
Model ALL
DESCRIPTION:
This bulletin provides guidelines that should be followed before removing the brake fluid reservoir
cap when adding or changing brake fluid.
IMPORTANT:
Make sure to completely remove foreign substances from around brake fluid reservoir and cap
before opening the reservoir cap. Not following this may cause contamination of brake fluid.
1. SERVICE PROCEDURE:
There are two potential locations for the brake fluid reservoir shown above.
HOW TO REMOVE FOREIGN SUBSTANCES FROM AROUND THE BRAKE FLUID RESERVOIR
CAP:
1. If the brake fluid reservoir cap is located in front of cowl top cover, first wipe foreign substances
off the brake fluid reservoir and its cap and then open the cap to add or change brake fluid.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins
> Brakes - Brake Fluid Adding/Changing Precautions > Page 2421
2. If the brake fluid reservoir cap is located under cowl top cover, first wipe foreign substances off
the lower surface of the cowl top cover, the brake fluid reservoir and its cap and then open the cap.
3. If brake fluid reservoir is equipped with oil filter, add or change brake fluid with the oil filter
inserted. DO NOT remove the oil filter while filling brake fluid.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins
> Page 2422
Brake Fluid: Specifications
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DIG are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
M
4H
m
h
E
5
I
m
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
1 *
i.
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SHIFT POEITIDH
8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 2438
1. 2 CURRENT IH-‘I‘I'FI
l H H H - H ‘ H
an EDIE”!!! Ell"!
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SHIFT PflSITIfl'I
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l-‘IH I - I m l m l m l m -
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 2439
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
2011—- Sonata
Fluid - A/T: All Technical Service Bulletins A/T - Specified ATF And Additive Usage
Number 10-AT-002
Model ALL
DESCRIPTION:
Hyundai approves the use of only the ATF specified in the vehicle's owner's manual. Use of other
ATF may result in improper shift quality or other driveability conditions.
Hyundai does not approve of the use of any aftermarket ATF additives.
The approved ATF and the ATF level checking procedure are summarized below:
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Fluid - A/T: All Technical Service Bulletins A/T - Specified ATF and Additive Usage Information
Number 09-AT-006
Model ALL
DESCRIPTION:
Hyundai Motor Company approves of the use of only the ATF specified in the vehicle's owner's
manual. Use of other ATF may result in improper shift quality or other driveability issues.
Hyundai Motor Company does not approve of the use of any aftermarket ATF additives.
"Use only Hyundai Genuine ATF or other brands meeting the specification approved by Hyundai
Motor Company."
The approved ATF and the ATF level checking procedure are shown above.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 06-40-016 > Nov > 06 > A/T - Automatic Transaxle Fluid Level
Fluid - A/T: All Technical Service Bulletins A/T - Automatic Transaxle Fluid Level
Group: TRANSMISSION
Number: 06-40-016
Model: ALL
DESCRIPTION:
The automatic transaxle fluid (ATF) level must be checked during Pre-Delivery Inspection (PDI).
Low ATF level may cause the following driveability conditions:
^ Engine "flare" during the 2-3 shift (engine speed increases during the shift) at light throttle when
the ATF is cold
^ Harsh or delayed shift during acceleration from a stop following a rapid deceleration
PROCEDURE:
1. Attach a Hi-Scan Pro or GDS and select "Automatic Transaxle" menu, "Current Data" menu and
"Fluid Temperature".
2. Drive the vehicle until the ATF is at normal operating temperature above 75°C (167°F).
3. Park the vehicle on a level surface and set the parking brake. Start the engine and move the
shift lever through each gear, then to "Neutral".
4. Check the ATF level on the dipstick. Add Hyundai SPIII until the level is within the "HOT" or
"75C" range.
NOTE:
The 2008 Veracruz requires JWS 3309, Type T-IV ATF. Do not use SPIII.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 06-40-016 > Nov > 06 > A/T - Automatic Transaxle Fluid Level > Page 2453
NOTE:
The "COLD" range is only used for estimating ATF level. The ATF level can be accurately checked
only if the ATF temperature is at normal operating temperature above 75°C (167°F).
NOTE:
Use only Hyundai SPIII ATF, Diamond SPIII ATF or other brands meeting the SPIII specification
approved by Hyundai Motor Company.
NOTE:
SPIII has a red color when new; however, the ATF may change color to a dark red or brown after
10,000 to 25,000 miles in service. This change is normal for this type of ATF and does not indicate
an internal transaxle condition.
MAINTENANCE INTERVAL:
Refer to the maintenance schedule in the owner's manuals for maintenance requirements.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE'
Fluid - A/T: All Technical Service Bulletins A/T - No Movement in 'DRIVE' or 'REVERSE'
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DIG are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
m
h
E
5
I
m
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
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SHIFT POEITIDH
8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' >
Page 2460
1. 2 CURRENT IH-‘I‘I'FI
l H H H - H ‘ H
an EDIE”!!! Ell"!
fllL I w m m
'1
SHIFT PflSITIfl'I
"5'1 T: T.. T'I1'Z T L Flt-T F: FH-J.
l-‘IH I - I m l m l m l m -
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fluid - A/T: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' >
Page 2461
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
2011—- Sonata
Fluid - A/T: All Technical Service Bulletins A/T - Specified ATF And Additive Usage
Number 10-AT-002
Model ALL
DESCRIPTION:
Hyundai approves the use of only the ATF specified in the vehicle's owner's manual. Use of other
ATF may result in improper shift quality or other driveability conditions.
Hyundai does not approve of the use of any aftermarket ATF additives.
The approved ATF and the ATF level checking procedure are summarized below:
Amant 1TE-1e4"F _
Elantra
Elnntra Tnurlng
Emata (10232-1W12
IE BUM
Atari
Entnuraga
Veranmz M43139 T-Ill- finial-131123 122*14D‘F F [IT-4mm
Fluid - A/T: All Technical Service Bulletins A/T - Specified ATF and Additive Usage Information
Number 09-AT-006
Model ALL
DESCRIPTION:
Hyundai Motor Company approves of the use of only the ATF specified in the vehicle's owner's
manual. Use of other ATF may result in improper shift quality or other driveability issues.
Hyundai Motor Company does not approve of the use of any aftermarket ATF additives.
"Use only Hyundai Genuine ATF or other brands meeting the specification approved by Hyundai
Motor Company."
The approved ATF and the ATF level checking procedure are shown above.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Fluid - A/T: > 06-40-016 > Nov > 06 > A/T - Automatic Transaxle Fluid Level
Fluid - A/T: All Technical Service Bulletins A/T - Automatic Transaxle Fluid Level
Group: TRANSMISSION
Number: 06-40-016
Model: ALL
DESCRIPTION:
The automatic transaxle fluid (ATF) level must be checked during Pre-Delivery Inspection (PDI).
Low ATF level may cause the following driveability conditions:
^ Engine "flare" during the 2-3 shift (engine speed increases during the shift) at light throttle when
the ATF is cold
^ Harsh or delayed shift during acceleration from a stop following a rapid deceleration
PROCEDURE:
1. Attach a Hi-Scan Pro or GDS and select "Automatic Transaxle" menu, "Current Data" menu and
"Fluid Temperature".
2. Drive the vehicle until the ATF is at normal operating temperature above 75°C (167°F).
3. Park the vehicle on a level surface and set the parking brake. Start the engine and move the
shift lever through each gear, then to "Neutral".
4. Check the ATF level on the dipstick. Add Hyundai SPIII until the level is within the "HOT" or
"75C" range.
NOTE:
The 2008 Veracruz requires JWS 3309, Type T-IV ATF. Do not use SPIII.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Fluid - A/T: > 06-40-016 > Nov > 06 > A/T - Automatic Transaxle Fluid Level > Page 2475
NOTE:
The "COLD" range is only used for estimating ATF level. The ATF level can be accurately checked
only if the ATF temperature is at normal operating temperature above 75°C (167°F).
NOTE:
Use only Hyundai SPIII ATF, Diamond SPIII ATF or other brands meeting the SPIII specification
approved by Hyundai Motor Company.
NOTE:
SPIII has a red color when new; however, the ATF may change color to a dark red or brown after
10,000 to 25,000 miles in service. This change is normal for this type of ATF and does not indicate
an internal transaxle condition.
MAINTENANCE INTERVAL:
Refer to the maintenance schedule in the owner's manuals for maintenance requirements.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
ATF ......................................................................................................................................................
...................... Diamond ATF SP-III, SK ATF SP-III
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Automatic Transaxle Fluid Check
INSPECTION
1. Drive the vehicle until the fluid reaches normal operating temperature [70 - 80°C]. 2. Place the
vehicle on a level surface. 3. Move the selector lever through all gear positions. This will fill the
torque converter and the hydraulic system with fluid and move the selector
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then
take out the oil level gauge and check the
NOTE: If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine
particles from the bushes and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the hot mark on the oil level gauge. If the fluid level is low, add
automatic transaxle fluid until the level reaches the
HOT mark. Auto transaxle fluid: DIAMOND ATF SP-III, SK ATF SP-III Quantity: 7.81 (8.2 US qt,
6.9 Imp. qt)
NOTE: Low fluid level can cause a variety of a abnormal conditions because it allows the pump to
take in air along with fluid. Air trapped in the hydraulic system forms bubbles, which are
compressable. Therefore, pressures will be erratic, causing delayed shifting, slipping clutches and
brakes, etc. Improper filling can also raise fluid level too high. When the transaxle has too much
fluid, gears chum up foam and cause the same conditions which occur with low fluid level, resulting
in accelerated deterioration of automatic transaxle fluid. In either case, air bubbles can cause
overheating, and fluid oxidation, which can interfere with normal valve, clutch, and brake operation.
Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a
leak.
REPLACEMENT
If you have a fluid changer, use this changer to replace the fluid. If you do not, replace it using this
procedure.
1. Disconnect the hose which connects the transmission and the oil cooler which is within the
radiator only in 2.4L engine (3.3L-the oil cooler is
separated).
2. Start the engine and let the fluid drain out. Running conditions: N range with engine idling.
CAUTION: The engine should be stopped within one minute after it is started. If the fluid has all
drained out before then, the engine should be stopped at that point.
3. Remove the drain plug (A) from the bottom of the transmission case to drain the fluid.
4. Install the drain plug via the gasket, and tighten it to the specified torque.
CAUTION: Stop pouring if the full volume of fluid cannot be poured in.
NOTE: Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and
(6).
7. Pour the new fluid in through the oil filler tube. 8. Reconnect the hose which was disconnected in
step (1) above and firmly replace the oil level gauge. (In case of this replace, this means after
wiping off any dirt around the oil level gauge, insert it into the filler tube.)
10. Move the select lever through all positions, and then move it to the N position. 11. Drive the
vehicle until the fluid temperature rises to the normal temperature (70 - 80°C), and then check the
fluid level again. The fluid level must
12. Firmly insert the oil level gauge (A) into the oil filler tube.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
Type .....................................................................................................................................................
.......... API SJ, SL or Above, ILSAC GF-3 or Above Grade
................................................................................................................. SAE 5W-20, SAE 5W-30
(All Temp. Range), SAE 10W-30 [Above 0°F]
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2488
Temperature range
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INSPECTION
Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor,
replace the oil.
After warming up the engine and then 5 minutes after the engine stop, oil level should be between
the L and F marks on the dipstick. If low, check for leakage and add oil up to the F mark.
Lubricants that do not have both an SAE grade number and API service classification on the
container should not be used.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2489
Engine Oil: Service and Repair
CAUTION: -
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
- Exercise caution in order to minimize the length and frequency of contact of your skin to used oil.
Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
- In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. Wait for 5 minutes after loosening the oil filter cap by turning it counterclockwise to drain well the
oil in the oil filter. 2. Remove the oil filler cap. 3. Remove the oil drain plug, and drain the oil into a
container.
a. Disconnect the oil filter cap from oil filter body. b. Remove the oil filter element. c. Check and
clean the oil filter installation surface. d. Check the part number of the new oil filter is as same as
old one. e. Install new oil filter element (A) and two O-rings (B). f.
Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat. Tightening
torque 24.50 Nm (2.5 kgf.m, 18.08 ft. lbs.)
a. Clean and install the oil drain plug with a new gasket.
Tightening torque 34.3 - 44.1 Nm (3.5 - 4.5 kgf.m, 25.3 - 32.5 ft. lbs.)
Capacity Drain and refill W/Oil filter change: 5.9 Liters (6.23 U. S. qts, 5.19 Imp. quarts) W/O Oil
filter change: 5.5 Liters (5.81 U. S. qts, 4.84 Imp. quarts) Oil filter: 0.4 Liters (0.42 U.S. qts, 0.35
Imp. quarts)
6. Start engine and check for oil leaks. 7. Recheck engine oil level.
Temperature range
need all d1 belnre
enlleheled Heeem'nemled EAE may umber
NOTE: For best performance and maximum protection of all types of operation, select only those
lubricants which: -
Lubricants that do not have both an SAE grade number and API service classification on the
container should not be used.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Power Steering - PSF-4 Fluid Compatibility/Part Number
Power Steering Fluid: Technical Service Bulletins Power Steering - PSF-4 Fluid Compatibility/Part
Number
Group: CHASSIS
Number: 07-50-002
Model: ALL
DESCRIPTION
This bulletin provides the PSF-4, Hyundai Genuine power Steering Fluid, part number and
interchangeability information.
INTERCHANGEABILITY
^ PSF-4 to PSF-3----> Topping off or adding up to 50% PSF-4 to a PSF-. system is acceptable.
NOTE:
Do not add more then 50% of the total system volume of PSF-4 to PSF-3. The PSF-3 fluid should
be drained and replaced with PSF-4 power steering fluid.
1. Position the vehicle on a level surface. 2. Start the engine. With the vehicle kept stationary, turn
the steering wheel several times continuously to raise the fluid temperature to 50 - 60°C
(122 - 140°F).
3. With the engine at idle, turn the steering wheel fully clockwise and counter-clockwise several
times. 4. Make sure that there is no foaming or cloudiness in the reservoir fluid. 5. Stop the engine
and check for any difference in fluid level between a stationary and a running engine.
NOTE: 1. If the fluid level varies 5 mm (0.2 inch) or more, bleed the system again. 2. If the fluid
level suddenly rises after stopping the engine, further bleeding is required. 3. Incomplete bleeding
will produce a chattering sound in the pump and noise in the flow control valve, and lead to
decreased durability of the
pump.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Page 2497
Power Steering Fluid: Service and Repair
1. Jack up the front wheels and support them with jack stands. 2. Disconnect the return hose from
the oil reservoir and plug the oil reservoir. 3. Connect a vinyl hose to the disconnected return hose,
and drain the oil into container. 4. Disconnect the high-tension cable at the ignition coil side. While
operating the starter motor intermittently, turn the steering wheel all the way to
the left and then to the right several times to drain the fluid.
5. Connect the return hoses, then fill the oil reservoir with the specified fluid. 6. Start the engine.
Check for oil leakage. 7. Stop the engine. 8. Bleed the system.
Power steering fluid type PSF-3 Total quantity: Approximately 1.0 liter
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
OIL SPECIFICATION
- The HFC-134a system requires synthetic (PAG) compressor oil whereas the R-12 system
requires mineral compressor oil. The two oils must never be mixed.
- Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the
model of compressor.
HANDLING OF OIL
- The oil should be free from moisture, dust, metal powder, etc.
- The water content in the oil increases when exposed to the air. After use, seal oil from air
immediately. (HFC-134a Compressor Oil absorbs moisture very easily.)
- The compressor oil must be stored in steel containers, not in plastic containers.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Electrical
Specifications > Page 2507
Refrigerant Oil: Capacity Specifications
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COMPRESSOR OIL
The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any
component of the system or a large amount of gas leakage occurs, add oil to maintain the original
amount of oil.
There is close affinity between the oil and the refrigerant. During normal operation, part of the oil
recirculates with the refrigerant in the system. When checking the amount of oil in the system, or
replacing any component of the system, the compressor must be run in advance for oil return
operation. The procedure is as follows:
1. Open all the doors and the engine hood. 2. Start the engine and air conditioning switch to "ON"
and set the blower motor control knob at its highest position. 3. Run the compressor for more than
20 minutes between 800 and 1,000 rpm in order to operate the system. 4. Stop the engine.
When replacing the system component parts, supply the following amount of oil to the component
parts to be installed.
For compressor replacement, subtract the volume of oil drained from the removed compressor
from the specified volume, and drain the calculated volume of oil from the new compressor:
The specified volume - volume of removed compressor = volume to drain from the new
compressor.
NOTE: Even if no oil is drained from the removed compressor, don't drain more than 50cc from
new compressor.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS System
.1
:n
95*”h
This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit,
brake lines and master cylinder with brake fluid. 1. Remove the reservoir cap and fill the brake
reservoir with brake fluid.
CAUTION: If there is any brake fluid on any painted surface, wash it off immediately.
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the
tube into a half filled clear plastic bottle.
3. Connect the hi-scan (pro) to the data link connector located underneath the dash panel. 4.
Select and operate according to the instructions on the hi-scan (Pro) screen.
CAUTION: You must obey the maximum operating time of the ABS motor with the hi-scan (Pro) to
prevent the motor pump from burning.
1) Select Hyundai vehicle diagnosis. 2) Select vehicle name. 3) Select Anti-Lock Brake system. 4)
Select air bleeding mode.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS System >
Page 2514
6) Wait 60 seconds before operating the air bleeding. (if not, you may damage the motor.)
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run
out without bubbles. Then close the bleeder screw.
Sequence
6. Repeat step 5 until there are no more bubbles in the fluid for each wheel. 7. Tighten the bleeder
screw.
Bleed screw tightening torque: 6.86 - 12.74 Nm (70 - 130 kgf-cm, 5.09 - 9.45 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS System >
Page 2515
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NOTE: ^
^ Always use Genuine DOT 3 or DOT 4 Brake Fluid. Using a non-Genuine DOT or 4 brake fluid
can cause corrosion and decrease the life of the system.
^ Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid.
^ Do not spill brake fluid on the vehicle, it may damage the paint, if brake fluid does contact the
paint, wash it off immediately with water.
^ The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of
bleeding procedure and checked after bleeding each brake caliper Add fluid as required.
1. Make sure the brake fluid in the reservoir is at the MAX (upper) level line (A). 2. Have someone
slowly pump the brake pedal several times, then apply pressure. 3. Loosen the right-rear brake
bleed screw to allow air to escape from the system. Then tighten the bleed screw securely.
4. Repeat the procedure for wheel in the sequence shown until air bubbles no longer appear in the
fluid.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS System >
Page 2516
FRONT DISC BRAKE
GENERAL PRECAUTIONS
Please read the following precautions carefully before performing the airbag system service.
Observe the instructions described in this manual, or the airbags could accidentally deploy and
cause damage or injury.
- Except when performing electrical inspections, always turn the ignition switch OFF and
disconnect the negative cable from the battery, and wait at least three minutes before beginning
work.
NOTE: The contents in the SRSCM memory are not erased even if the ignition switch is turned
OFF or the battery cables are disconnected from the battery.
- Use the replacement parts which are manufactured to the same standards as the original parts
and quality. Do not install used SRS parts from another vehicle. Use only new parts when making
SRS repairs.
- Carefully inspect any SRS part before you install it. Do not install any part that shows signs of
having been dropped or improperly handled, such as dents, cracks or deformation.
- Before removing any of the SRS parts (including the disconnection of the connectors), always
disconnect the SRS connector.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Page 2526
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Page 2527
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Page 2528
Passenger Compartment Relay Box View
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2531
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2534
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2535
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2536
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2537
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2539
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2540
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2541
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2542
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2543
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2544
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2545
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Page 2546
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Page 2549
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Page 2550
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Page 2551
Passenger Compartment Relay Box View
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Testing and
Inspection > Relay Box (Engine Compartment)
INSPECTION
2. There should be no continuity between the No.1 and No.2 terminals when power is
disconnected.
1. There should be continuity between the No.1 and No.2 terminals when power and ground are
connected to the No.3 and No.5 terminals.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Testing and
Inspection > Relay Box (Engine Compartment) > Page 2554
2. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
1. There should be continuity between the No.1 and No.4 terminals when power and ground are
connected to the No.2 and No.3 terminals.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Testing and
Inspection > Relay Box (Engine Compartment) > Page 2555
2. There should be no continuity between the No.1 and No.4 terminals when power is
disconnected.
2. There should be continuity between the No.1 and No.5 terminals when power is disconnected.
FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse
capacities for each circuit correct? 3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why
the fuse blew first and completely eliminate the problem before installing a new fuse.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Testing and
Inspection > Relay Box (Engine Compartment) > Page 2557
Fuse: Testing and Inspection Relay Box (Passenger Compartment)
FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse
capacities for each circuit correct? 3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why
the fuse blew first and completely eliminate the problem before installing a new fuse.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2562
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2565
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2566
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2567
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2568
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2570
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2571
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2573
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2574
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2575
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 2576
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Page 2577
Fuse Block: Testing and Inspection
FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse
capacities for each circuit correct? 3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why
the fuse blew first and completely eliminate the problem before installing a new fuse.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information >
Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information >
Locations > Page 2582
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Locations > Page 2589
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Locations > Page 2590
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Locations > Page 2591
Passenger Compartment Relay Box View
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions
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Relay Box: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
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and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2597
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2598
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2599
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2600
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2602
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2603
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2604
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2605
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2606
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2607
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Diagram Information and Instructions > Page 2608
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Page 2609
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Page 2612
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Page 2613
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Engine Compartment Junction Block View
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information >
Diagrams > Page 2614
Passenger Compartment Relay Box View
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Testing
and Inspection > Relay Box (Engine Compartment)
INSPECTION
2. There should be no continuity between the No.1 and No.2 terminals when power is
disconnected.
1. There should be continuity between the No.1 and No.2 terminals when power and ground are
connected to the No.3 and No.5 terminals.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Testing
and Inspection > Relay Box (Engine Compartment) > Page 2617
2. There should be continuity between the No.1 and No.4 terminals when power is disconnected.
1. There should be continuity between the No.1 and No.4 terminals when power and ground are
connected to the No.2 and No.3 terminals.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Testing
and Inspection > Relay Box (Engine Compartment) > Page 2618
2. There should be no continuity between the No.1 and No.4 terminals when power is
disconnected.
2. There should be continuity between the No.1 and No.5 terminals when power is disconnected.
FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse
capacities for each circuit correct? 3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why
the fuse blew first and completely eliminate the problem before installing a new fuse.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Testing
and Inspection > Relay Box (Engine Compartment) > Page 2620
Relay Box: Testing and Inspection Relay Box (Passenger Compartment)
FUSE INSPECTION
1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse
capacities for each circuit correct? 3. Are there any blown fuses?
If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why
the fuse blew first and completely eliminate the problem before installing a new fuse.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
The OEM does not provide a Maintenance Required Indicator for this model.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions
Vehicle Lifting: Service Precautions
1. Block the wheels. 2. Place a jack under the specified jacking point. 3. Support the vehicle with
safety stands (jack stands). 4. Start the engine when engine compartment is clean.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service
Precautions > Page 2629
autumn-m.
WARNING: 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
substantial 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.
NOTE:
- Since each tire/wheel assembly weights approximately 30 lbs (14 kg), 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 and inspect the lift points for secure support.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection
> Tire Rotation
TIRE ROTATION
TIRE WEAR
2. If the remaining tread (A) depth is less than the limit, replace the tire.
NOTE: When the tread depth of the tires is less than 1.6 mm (0.063 inch), the wear indicators (B)
will appear.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection
> Tire Rotation > Page 2643
Tires: Testing and Inspection Checking For Pull and Wander
If the steering pulls to one side, rotate the tires according to this wheel rotation procedure. 1.
Rotate the front right and front left tires, and perform a road test in order to confirm vehicle stability.
2. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test
again.
3. If the steering continues to pull to one side, rotate the front right and left tires again, and perform
a road test.
4. If the steering continues to pull to the opposite side, replace the front wheels with new ones.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Wheels - Aluminum Wheel Cap Replacement
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Wheels: Technical Service Bulletins Wheels - Aluminum Wheel Cap Replacement
DESCRIPTION:
The aluminum wheel cap acrylic "H" logo may separate when exposed to elevated temperatures. If
this occurs on a vehicle, replace all four wheel caps at the same time.
VEHICLES AFFECTED:
Model: SONATA(NF)
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Drill a hole in the wheel cap large enough to insert a screw driver or pick. A 1/4" drill bit is
recommended.
CAUTION:
Use care not to damage the wheel or hub under the wheel cap.
WARNING:
2. Insert a screwdriver or pick into the hole and carefully pry the wheel cap from the wheel.
CAUTION:
WARNING:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Wheels - Aluminum Wheel Cap Replacement > Page 2648
3. Push the new wheel cap into the wheel center until fully seated.
Group: BODY
Number: 09-BD-003
DESCRIPTION:
This TSB describes how to clean and maintain the aluminum wheels on Hyundai vehicles. The
following information on wheel care may be given to customers as needed. Hyundai has found that
some vehicles equipped with wheels that have been coated with a vapor chrome finish have
exhibited surface damage from the use of harsh chemicals and improper cleaning procedures.
Though these wheels have the appearance of chrome plating, they have a painted surface similar
to the exterior of the vehicle, therefore, the same care should be used when cleaning and
maintaining.
1. Wash wheels when they are cool, in a shaded area away from direct sunlight.
2. Wash wheels with a neutral detergent or an alkaline wash soap (car soap) using a soft cleaning
sponge.
3. Rinse the soap off the wheel with water spray, then dry wheels using a 100% cotton terry cloth
towel, chamois or a synthetic fabric designed for automotive detailing.
4. Some automatic car washes may also cause damage to the vapor chrome finish.
5. Car wash chemical strength cleaners along, with brush agitation could damage the finish.
NOTE: Wheels that are found to be damaged by incorrect cleaning may be considered to have
been damaged by abuse and will not be covered by the vehicle's warranty.
APPLICABLE VEHICLES:
Group: CHASSIS
Number: 05-50-006
DESCRIPTION:
This bulletin provides the updated wheel runout specifications for the 2006 Sonata. Please note
that the specification for the steel wheel, which is only available on models equipped with 4 cylinder
engines has been revised.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Wheels - Aluminum Wheel Cap Replacement > Page 2651
Steel Wheels
Aluminum Wheels
WHEEL RUNOUT
1. Jack up the vehicle and support it with jack stands. 2. Measure the wheel runout with a dial
indicator as illustrated. 3. Replace the wheel if the wheel runout exceeds the limit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle
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COMPONENTS
REMOVAL
1. Remove the wheel and tire.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle > Page 2657
2. Disconnect the wheel speed sensor (A) from the knuckle.
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5. Remove the split pin and driveshaft castle nut from the front hub.
6. Remove the 2 bolts (A) and disconnect the ball joint from the knuckle.
7. Using a plastic hammer, disconnect the driveshaft from the axle hub.
8. Using the special tool (09568-4A000), disconnect the tie rod end from the knuckle.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle > Page 2659
9. Loosen the upper arm mounting nut but do not remove it.
10. Using the special tool (095684A000), disconnect the upper arm from the knuckle.
11. Remove the front axle and knuckle together. 12. Installation is the reverse of removal.
DISASSEMBLY
1. Remove the brake disc from the hub. 2. Remove the snap ring.
3. Using the special tool (09545-34100), disconnect the hub from the knuckle.
4. Using the special tools (09432-11000, 09545-34100), remove the wheel bearing inner race from
the hub.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle > Page 2660
5. Using the special tools (09216-21600, 09216-22100), remove the wheel bearing outer race from
the knuckle.
INSPECTION
1. Check the hub for cracks and splines for wear. 2. Check the snap ring for cracks or damage. 3.
Check the knuckle inner surface for scoring and cracks.
REASSEMBLY
1. Apply a thin coat of multi-purpose grease to the knuckle and bearing contact surface. 2. Using
the special tool (09216-21100), press-in the bearing to the knuckle.
NOTE: ^
Do not press against the inner race of the wheel bearing because that can cause damage to the
bearing assembly.
3. Install the snap ring into the groove of the knuckle. 4. Using the special tool (09545-21100),
press the hub on to the knuckle.
NOTE: Do not press against the outer race of the wheel bearing because that can cause damage
to the bearing assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle > Page 2661
5. Tighten the hub to the knuckle to 200 Nm (20 kgf-cm, 148 ft. lbs.) with the special tool
(09517-21500).
6. Rotate the hub to seat the bearing. 7. Measure the wheel bearing starting torque.
Standard value
Fix a dial gauge and measure the hub end play. Check that it is within the standard value. Standard
value
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REAR HUB/AXLE
COMPONENTS
REMOVAL
1. Release the parking brake. 2. Remove the wheel and tire.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle > Page 2664
3. Remove the ABS sensor from the carrier. 4. Remove the caliper assembly from the carrier and
suspend it with wire. 5. Remove the brake disc. 6. Remove the rear axle hub mounting bolts (4).
8. Remove the carrier assembly. 9. After unstaking the flange nut, remove the nut.
10. While supporting the flange area of the bearing outer race, press out the rear axle hub.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle > Page 2665
11. Using the special tool (09432-11000), remove the bearing inner race from the axle hub.
12. Using the special tools (09453-33000B, 09545-21100), remove the 2 bushings from the carrier.
INSPECTION
1. Check the rear hub bearing for wear or damage. 2. Check the rear tone wheel for chipped teeth.
3. Check the hub inner surface for scoring. 4. Check the carrier for crack.
INSTALLATION
1. Using the special tools (09453-33000B, 09545-21100) press-in the 2 bushings to the carrier.
2. Apply a thin coat of multi-purpose grease to the hub and bearing contact surface. 3. Using the
special tool (09545-21100), press-in the bearing to the hub.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle > Page 2666
NOTE: Do not press against the outer race of the bearing because that can cause the damage to
the bearing assembly. Always use a new bearing assembly.
4. After tightening the flange nut, stake the nut to meet the concave portion of the spindle.
6. Fix the hub and bearing assembly to the brake backing plate so that the rounded area of the
bearing outer race is placed facing upward.
NOTE: If it is difficult to fix, adjust the parking brake adjusting nut in clockwise direction to enlarge
the space between the shoe and lining assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Hub & Knuckle > Page 2667
Standard valua
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7. Tighten the 4 bolts to the specified torque.
8. Rotate the hub to seat the bearing. 9. Using a spring balance, measure the wheel bearing
starting torque.
Standard value
Standard value
10. Fix a dial gauge and measure the hub end play. Check that it is within the standard value.
Standard value
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Huhand play: EDD! mm {DJIII Inlnrlas:
Standard value
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical
Service Bulletins > Customer Interest: > 06-50-005 > Mar > 06 > Wheels/Tires - Aluminum Wheel Cap Separation
Group: CHASSIS
Number: 06-50-005
Date: MARCH, 2006
DESCRIPTION:
The aluminum wheel cap acrylic "H" logo may separate when exposed to elevated temperatures. If
this occurs on a vehicle, replace all four wheel caps at the same time.
Affected vehicle production date range: Start of Production through October 1st, 2005
PART REQUIRED
SERVICE PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical
Service Bulletins > Customer Interest: > 06-50-005 > Mar > 06 > Wheels/Tires - Aluminum Wheel Cap Separation > Page
2677
1. Drill a hole in the wheel cap large enough to insert a screw driver or pick a 1/4" drill bit is
recommended.
CAUTION:
WARNING:
2. Insert a screwdriver or pick into the hole and carefully pry the wheel cap from the wheel.
CAUTION:
WARNING:
3. Push the new wheel cap into the wheel center until fully seated.
Fauna": l fl fl T W fl E fl I — m |
| Madcap | mnamm | a |
Wheel Cover: All Technical Service Bulletins Wheels - Aluminum Wheel Cap Replacement
DESCRIPTION:
The aluminum wheel cap acrylic "H" logo may separate when exposed to elevated temperatures. If
this occurs on a vehicle, replace all four wheel caps at the same time.
VEHICLES AFFECTED:
Model: SONATA(NF)
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Drill a hole in the wheel cap large enough to insert a screw driver or pick. A 1/4" drill bit is
recommended.
CAUTION:
Use care not to damage the wheel or hub under the wheel cap.
WARNING:
2. Insert a screwdriver or pick into the hole and carefully pry the wheel cap from the wheel.
CAUTION:
WARNING:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Cover: > tnt1620406-04 > Apr > 06 > Wheels - Aluminum
Wheel Cap Replacement > Page 2684
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Wheel Cover: All Technical Service Bulletins Wheels/Tires - Aluminum Wheel Cap Separation
Group: CHASSIS
Number: 06-50-005
Date: MARCH, 2006
DESCRIPTION:
The aluminum wheel cap acrylic "H" logo may separate when exposed to elevated temperatures. If
this occurs on a vehicle, replace all four wheel caps at the same time.
Affected vehicle production date range: Start of Production through October 1st, 2005
PART REQUIRED
SERVICE PROCEDURE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 06-50-005 > Mar > 06 > Wheels/Tires - Aluminum
Wheel Cap Separation > Page 2689
1. Drill a hole in the wheel cap large enough to insert a screw driver or pick a 1/4" drill bit is
recommended.
CAUTION:
WARNING:
2. Insert a screwdriver or pick into the hole and carefully pry the wheel cap from the wheel.
CAUTION:
WARNING:
3. Push the new wheel cap into the wheel center until fully seated.
Fauna": l fl fl T W fl E fl I — m |
| Madcap | mnamm | a |
Wheel Cover: All Technical Service Bulletins Wheels - Aluminum Wheel Cap Replacement
DESCRIPTION:
The aluminum wheel cap acrylic "H" logo may separate when exposed to elevated temperatures. If
this occurs on a vehicle, replace all four wheel caps at the same time.
VEHICLES AFFECTED:
Model: SONATA(NF)
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Drill a hole in the wheel cap large enough to insert a screw driver or pick. A 1/4" drill bit is
recommended.
CAUTION:
Use care not to damage the wheel or hub under the wheel cap.
WARNING:
2. Insert a screwdriver or pick into the hole and carefully pry the wheel cap from the wheel.
CAUTION:
WARNING:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheel Cover: > tnt1620406-04 > Apr > 06 > Wheels - Aluminum Wheel
Cap Replacement > Page 2696
5.1mm m m m can IL! mama *I'IBE “BEE
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When using an impact gun, final tightening torque should be checked using a torque wrench.
Tightening order. Check the torque again after tightening the wheel nuts diagonally.
Torque
...................................................................................................................................................... 0 -
110 Nm (9 - 11 kgf-cm, 65.1 - 79.5 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Page 2704
1. Tightening torque.
2. Tightening order. Check the torque again after tightening the wheel nuts diagonally.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins >
Drivetrain - Recreational Towing Requirements
Group: GENERAL
Number: 08-GI-003
Model: ALL
DESCRIPTION:
This bulletin provides requirements for towing 2WD Hyundai vehicles equipped with manual
transaxles with all four wheels on the ground, such as may be done to tow behind a recreational
vehicle.
CAUTION:
The combinations listed in the TABLE MUST NOT be towed behind a recreational vehicle with all
four wheels on the ground.
NOTE:
Confirm that the "recreational" tow vehicle has the capacity to tow a Hyundai vehicle.
Any Hyundai 2WD vehicle equipped with a manual transaxle may be towed with all four wheels on
the ground behind another vehicle, such as a Recreational Vehicle (RV), as long as the following
conditions are met:
4. Gearshift is in NEUTRAL
5. Steering wheel is UNLOCKED with the key in the ignition and in the "ACC" position
7. Front tire pressures are equal and inflated to the recommended pressure
NOTE:
When you leave the key in the "ACC" position, make sure all accessories are turned off to prevent
battery drain.
8. Vehicle is towed from the front with all four wheels on the ground
WARNING:
When towing has been completed, be sure to turn the key off, remove it from the ignition and set
the parking brake. Do not leave the key in the ignition with the vehicle unattended.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins >
Drivetrain - Recreational Towing Requirements > Page 2709
NOTE:
Emergency and disabled vehicle towing procedures are given in detail in the respective model's
owner's manual; however, the following information quickly summarizes the various recommended
towing procedures to be used by Hyundai dealers or by commercial truck towing companies.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins >
Page 2710
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
Flat - bed Equipment- The operator loads the vehicle on the back of truck. This is the best way of
transporting the vehicle.
Wheel Lift Equipment- The tow truck uses two pivoting arms that go under the tires (front or rear)
and lift them oft the ground. The other two wheels remain on the ground.
Sling type Equipment- 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, it should be towed with the front wheels off the
ground. If due to damage, the vehicle must be tow with the front wheels on the ground, do the
following:
Manual Transmission
Automatic Transmission
CAUTION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins >
Page 2711
- Improper towing preparation will damage the transmission. Follow the above procedure exactly. If
you cannot shift the transmission or start the engine(automatic transmission), your vehicle must be
transported on a flatbed.
- It is the best to tow vehicle no farther than l9mlles (30km), and keep the speed below 30 mph (50
km/h).
- Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not
designed to support the vehicle's weight.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions
Vehicle Lifting: Service Precautions
1. Block the wheels. 2. Place a jack under the specified jacking point. 3. Support the vehicle with
safety stands (jack stands). 4. Start the engine when engine compartment is clean.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 2715
EAW-UEIF-‘h
WARNING: 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
substantial 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.
NOTE:
- Since each tire/wheel assembly weights approximately 30 lbs (14 kg), 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 and inspect the lift points for secure support.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Engine - CVVT Oil Control Valve Inspection
mm eweaaasaa
Elantra Touring {FD}
mu
Theta ESL I EAL Genesis Coupe {SK}. Sonata {HF} Dense
Mu 21L ' Santa Fe {GM} Delphi
Sonata {NF}. Santa Fe {SM}. Azera HG}.
Lambda 3.3L i' 3.3L 1|hieracniz {EN}. Entourage [EP]. Delphi
Genesis Coupe {EH}. Genesis Sedan {SH}
Tau 4.6L Genesis Sedan (SI-l} Dense
Variable Valve Timing Actuator: Technical Service Bulletins Engine - CVVT Oil Control Valve
Inspection
Group ENGINE
Number 09-EM-002
DESCRIPTION:
When diagnosing the Continuously Variable Valve Timing (CVVT) system for rough idling, poor
acceleration, camshaft timing misalignment-related trouble codes, misfire related trouble codes,
and/or other related symptoms, it may be required to inspect the Oil Control Valve (OCV) for proper
operation. Follow the procedure outlined in this bulletin to inspect the OCV. If the OCV operates
normally, then carry out other necessary repairs. Do not replace the OCV if normal operation is
confirmed.
APPLICABLE VEHICLES:
Carry on
nth-r musty “pm.
HD
— I r | Ram-c:- than DEV.
Hun-Inn thl furnish “trill Ind Ihln Vll'lfy' thlt thl flult II turf-did.
NOTE: DD HflTrmllfl HI! OCVHMHM dlmlflab [ha HEM
am: BUFFIJER
{BEE PAGE 1) can RESISTANCE AT am {EDT} I
1. Measure the resistance between the OCV Power and Signal terminals.
2. Check if the OCV operates normally by providing 12V power as shown in the picture above.
IMPORTANT:
Careful attention is necessary to avoid a short circuit when providing the OCV with 12V power.
Spacing between the OCV power and signal terminals is very narrow. Use suitable connections to
prevent shorting of the test power supply.
3. When 12V power is provided to the OCV, the OCV must move forward as shown in the picture
shown above.
NOTE:
4. If the OCV does not move forward, examine if a foreign object like an aluminum chip (C) is
jammed inside the OCV.
^ Blow out the foreign object using compressed air, reinstall the OCV and then verify that the fault
is corrected.
WARRANTY INFORMATION:
Detail
I
"
_
"
I
J
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Page 2728
r
CDMFOHENT LUCATIDN EEW'iFII
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Page 2729
DESCRIPTION
Continuously Variable Valve Timing (CVVT system controls valve overlap with forcibly activating
the camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas
(NOx, HC) and improves fuel economy, idle state, torque in low speed and power in high speed.
This system uses engine oil pressure and consists of the two CVVT Oil Control Valve (OCV) in
each bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
SPECIFIGATIHH
“ spawn
mm
DESCRIPTION
Continuously Variable Valve Timing (CVVT system controls valve overlap with forcibly activating
the camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas
(NOx, HC) and improves fuel economy, idle state, torque in low speed and power in high speed.
This system uses engine oil pressure and consists of the two CVVT Oil Control Valve (OCV) in
each bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
Specification
INSTALLATION
CAUTION: If the OCVs are installed incorrectly, the vehicle may be damaged. So when installing
them, be careful its connector color (Components and harness side).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
ENGINE COMPRESSION
Compression pressure
................................................................................................................................................. 1,283
kPa (13.0 kgf/cm2, 185 psi) Minimum pressure
......................................................................................................................................................
1,135 kPa (1 1.5 kgf/cm2, 164 psi) Difference between each cylinder
............................................................................................................................ 100 kPa (1.0
kgf/cm2, 15 psi) or less
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 2734
Compression Check: Testing and Inspection
COMPRESSION
NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking
the engine, measure the compression pressure.
NOTE: Always use a fully charged battery to obtain engine speed of 200 rpm or more.
Compression pressure 1,283 kPa (13.0 kgf/cm2, 185 psi) Minimum pressure: 1,135 kPa (1 1.5
kgf/cm2, 164 psi) Difference between each cylinder 100 kPa (1.0 kgf/cm2, 15 psi) or less
e. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into
the cylinder through the spark plug hole and
repeat steps (a) through (c) for cylinders with low compression. ^
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
^ If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
LH Camshaft
Intake ...................................................................................................................................................
........................................................... 46.3 mm Exhaust .....................................................................
...................................................................................................................................... 45.8 mm
RH Camshaft
Intake ...................................................................................................................................................
........................................................... 46.3 mm Exhaust .....................................................................
...................................................................................................................................... 45.8 mm
LH, RH camshaft
Intake No. 1
........................................................................................................................................................
27.964 - 27.980 mm (1.1009 - 1.1016 inch) No. 2,3,4
.................................................................................................................................................. 23.954
- 23.970 mm (0.9430 - 0.9437 inch) Exhaust No. 1
........................................................................................................................................................
27.964 - 27.980 mm (1.1009 - 1.1016 inch) No. 2,3,4
.................................................................................................................................................. 23.954
- 23.970 mm (0.9430 - 0.9437 inch)
LH, RH camshaft
Intake No. 1
................................................................................................................................................. 0.020 -
0.057 mm (0.0008 - 0.0022 inch) No. 2,3,4
......................................................................................................................................................
0.030 - 0.067 mm (0.0012 - 0.0026 inch) Exhaust No. 1
............................................................................................................................................................
0.020 - 0.057 mm (0.0008 - 0.0022 inch) No. 2,3,4
......................................................................................................................................................
0.030 - 0.067 mm (0.0012 - 0.0026 inch)
mm eweaaasaa
Elantra Touring {FD}
mu
Theta ESL I EAL Genesis Coupe {SK}. Sonata {HF} Dense
Mu 21L ' Santa Fe {GM} Delphi
Sonata {NF}. Santa Fe {SM}. Azera HG}.
Lambda 3.3L i' 3.3L 1|hieracniz {EN}. Entourage [EP]. Delphi
Genesis Coupe {EH}. Genesis Sedan {SH}
Tau 4.6L Genesis Sedan (SI-l} Dense
Variable Valve Timing Actuator: Technical Service Bulletins Engine - CVVT Oil Control Valve
Inspection
Group ENGINE
Number 09-EM-002
DESCRIPTION:
When diagnosing the Continuously Variable Valve Timing (CVVT) system for rough idling, poor
acceleration, camshaft timing misalignment-related trouble codes, misfire related trouble codes,
and/or other related symptoms, it may be required to inspect the Oil Control Valve (OCV) for proper
operation. Follow the procedure outlined in this bulletin to inspect the OCV. If the OCV operates
normally, then carry out other necessary repairs. Do not replace the OCV if normal operation is
confirmed.
APPLICABLE VEHICLES:
Carry on
nth-r musty “pm.
HD
— I r | Ram-c:- than DEV.
Hun-Inn thl furnish “trill Ind Ihln Vll'lfy' thlt thl flult II turf-did.
NOTE: DD HflTrmllfl HI! OCVHMHM dlmlflab [ha HEM
am: BUFFIJER
{BEE PAGE 1) can RESISTANCE AT am {EDT} I
1. Measure the resistance between the OCV Power and Signal terminals.
2. Check if the OCV operates normally by providing 12V power as shown in the picture above.
IMPORTANT:
Careful attention is necessary to avoid a short circuit when providing the OCV with 12V power.
Spacing between the OCV power and signal terminals is very narrow. Use suitable connections to
prevent shorting of the test power supply.
3. When 12V power is provided to the OCV, the OCV must move forward as shown in the picture
shown above.
NOTE:
4. If the OCV does not move forward, examine if a foreign object like an aluminum chip (C) is
jammed inside the OCV.
^ Blow out the foreign object using compressed air, reinstall the OCV and then verify that the fault
is corrected.
WARRANTY INFORMATION:
Detail
I
"
_
"
I
J
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Page 2754
r
CDMFOHENT LUCATIDN EEW'iFII
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SI SI- S sons 1:! S ‘
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Technical Service Bulletins > Page 2755
DESCRIPTION
Continuously Variable Valve Timing (CVVT system controls valve overlap with forcibly activating
the camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas
(NOx, HC) and improves fuel economy, idle state, torque in low speed and power in high speed.
This system uses engine oil pressure and consists of the two CVVT Oil Control Valve (OCV) in
each bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
SPECIFIGATIHH
“ spawn
mm
DESCRIPTION
Continuously Variable Valve Timing (CVVT system controls valve overlap with forcibly activating
the camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas
(NOx, HC) and improves fuel economy, idle state, torque in low speed and power in high speed.
This system uses engine oil pressure and consists of the two CVVT Oil Control Valve (OCV) in
each bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
Specification
INSTALLATION
CAUTION: If the OCVs are installed incorrectly, the vehicle may be damaged. So when installing
them, be careful its connector color (Components and harness side).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod
Bearing > Component Information > Specifications
n|5cmulumuu DF GRANHSHAFI'
alscmmnnnou OF GRAHKSHAFT
I ou'rslnE DIAIIETER
“m“ m a. P...
54555~54.512mm
[2.154D" 11542.1.)
54.555- 54.555mm
[2.1633 '- 2.1E-IIDI'I)
54.954- 54350411411
{2.1535 - 2.163551-)
DISCRIMINATION OF CRANKSHAFT
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod
Bearing > Component Information > Specifications > Page 2761
TI-flflflflfll I‘JF
BEARING
1.514 .. 1.51?I'nm
[n.uaafi - atrium.)
1.511 -1.51I|-l'fln
IDJIJEHE '- RUBBISH.)
1.5a: - 1.511mm
{111554 - flflfiflfiln.)
Connecting Rod: Technical Service Bulletins Engine - Torque To Yield Bolt Torque Specifications
Number 09-EM-006
This bulletin is an extension of TSB 02-20-002 to include latest models and guidelines.
DESCRIPTION:
The information outlined in this bulletin provides reuse guidelines and torque specifications for the
cylinder head, connecting rod, and main bearing bolts that must be fastened using the torque-angle
method.
VEHICLES AFFECTED
REQUIRED TOOLS: ^ Torque Wrench (1/4" for small torque and 3/8" for medium torque values)
NOTE:
Commercially available torque angle gauges such as the Snap-On (P/N TA360) can be used as an
aid to determine the angular values.
SERVICE INFORMATION:
^ Always use fresh engine oil to coat the bolt threads and both sides of the washer of a
torque-angle fastener.
^ Follow the loosening and tightening sequence specified in the applicable Shop Manual for the
cylinder head bolts and the main bearing cap bolts.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod,
Engine > Component Information > Technical Service Bulletins > Engine - Torque To Yield Bolt Torque Specifications >
Page 2766
357—7-955925:125.! .
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__1:}
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'1“: “3’1 3
Connecting Rod
Crankshaft Main Bearing: Technical Service Bulletins Engine - Torque To Yield Bolt Torque
Specifications
Number 09-EM-006
This bulletin is an extension of TSB 02-20-002 to include latest models and guidelines.
DESCRIPTION:
The information outlined in this bulletin provides reuse guidelines and torque specifications for the
cylinder head, connecting rod, and main bearing bolts that must be fastened using the torque-angle
method.
VEHICLES AFFECTED
REQUIRED TOOLS: ^ Torque Wrench (1/4" for small torque and 3/8" for medium torque values)
NOTE:
Commercially available torque angle gauges such as the Snap-On (P/N TA360) can be used as an
aid to determine the angular values.
SERVICE INFORMATION:
^ Always use fresh engine oil to coat the bolt threads and both sides of the washer of a
torque-angle fastener.
^ Follow the loosening and tightening sequence specified in the applicable Shop Manual for the
cylinder head bolts and the main bearing cap bolts.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main
Bearing > Component Information > Technical Service Bulletins > Engine - Torque To Yield Bolt Torque Specifications >
Page 2777
357—7-955925:125.! .
' fl .-_. Il—'l : - ' 'i' "
__1:}
. a he; fi _ ' -
. _
Tau 4.6L
._ Ha lls lw .3
'1“: “3’1 3
m IIIEInE DIAHEIEE
EEJIIJD --.D{IEI11m
[2.2524 - 2.2231In.)
55.212 —- 53.2mm
{22222 -» 2.234221.)
DUTEIDE DIIIIIIETEH.
54.956 - 54.9mm
{2.15M} - 2.1-E-IIEII'IJ
54.95:] - 54.95'EIIIm
[2.1522 - 2.1mm.)
54.954 - 54.95IJI'IIn'I
{2.1635 - 2.1633in.}
Crankshaft Main Bearing: Specifications Main Bearing Specifications
Oil clearance
.....................................................................................................................................................
0.022 - 0.040 mm (0.0008 - 0.0016 inch) End play .............................................................................
.................................................................................. 0.10 - 0.28 mm (0.0039 - 0.0110 inch)
Standard end play
................................................................................................................................................. 0.10 -
0.28 mm (0.0039 - 0.0110 inch) Thrust bearing thickness
........................................................................................................................................ 2.41 - 2.45
mm (0.0949 - 0.0964 inch) Main journal diameter
................................................................................................................................... 68.942 - 68.960
mm (2.7142 - 2.7149 inch)
DISCRIMINATION OF CRANKSHAFT
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main
Bearing > Component Information > Specifications > Main Bearing Specifications > Page 2782
1.511 - 1.514rnm
111.0595 - BEBE-'11.}
1.500 '- 15.11a
{10594- 0.0.}5051"
1.5115— 1.51111mm
“WEE" {1111593- uUusmm}
{0.11591 - 11.059311]
73.51313 - T3.506n1m
[2.I3T - 2,1393%}
:-= 39 — 2.594211.)
13.512 — T3.51Mm
{2.5942 - 2.3914111.)
PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING)
DISEHIIIHAHDH IDF m m
950mm
as.954 - Ham
{2.114r~ 2 Hanan.}
inma— mas-Inn
F.?145-_2_.?147h.}
{23142- 211431.}
DISCRIMINATION OF CRANKSHAFT
m
H
a
m
m
m
m
m
m
THCHHEIE {F
W 2.21? 22mm
11 flflfi'fln }
2 2711 - 2.2??rrm
[H.DB‘BE '- Dflflflh}
2.2“ '- 2.2T4rrm
[1W '- DflflflfiinJ
toms: .. magma]
E m m w
11.10 '- flflm‘n (0.1m: '* 0.01'Ilfln.)
DISCRIMINATION OF CRANKSHAFT BEARING
SELECTION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main
Bearing > Component Information > Specifications > Main Bearing Specifications > Page 2785
Ewm - M —
3 . . —_ — —
Main hearing cap bolt 133.30 + 1233' 2.0 + 1233' |I4.46 + 1233'
{3.33331 bearing flap 3.31: ' 334% 31.33 333 3.3 31.313 ~ 23.14
Crankshaft Main Bearing: Specifications Main Bearing Cap Bolts Tightening Specifications
Tightening Specifications
Sequence
mun- 11.1:
[LII ~12. 1.2:— m}
TLHv-r'fm
{1.3 -. 11'. man -. 55m
3/
m-1I.Ti[1.lI-11, Til-Ell}
15-"! -Il.35{3.fl-1121Jfl—fl.1l}
m
m.
m
m
E. Fla-arullafllcala
m.
mu
mm
?'. {hank-hail;
m
m
COMPONENTS
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
m IIIEInE DIAHEIEE
EEJIIJD --.D{IEI11m
[2.2224 - 2.2222In.)
55.212 —- 52.2mm
{2.2222 - 2.224221.)
DUTEIDE DIIIIIIETEH.
54.956 - 54.9mm
{2.15M} - 2.1-E-IIEII'IJ
54.95:] - 54.95'EIIIm
[2.1222 - 2.1E4DI'I.)
54.954 - 54.95IJI'IIn'I
{2.1635 - 2.1633in.}
Crankshaft: Specifications
Crankshaft
DISCRIMINATION OF CRANKSHAFT
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 2790
1.511 - 1.514rnm
111.0595 - BEBE-'11.}
1.500 '- 15.11a
{10594- 0.0.}5051"
1.5115— 1.51111mm
“WEE" {1111593- uUusmm}
{0.11591 - 11.059311]
73.51313 - T3.506n1m
[2.I3T - 2,1393%}
:-= 39 — 2.594211.)
13.512 — T3.51Mm
{2.5942 - 2.3914111.)
PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING)
DISEHIIIHAHDH IDF m m
950mm
as.954 - Ham
{2.114r~ 2 Hanan.}
inma— mas-Inn
F.?145-_2_.?147h.}
{23142- 211431.}
DISCRIMINATION OF CRANKSHAFT
m
H
a
m
m
m
m
m
m
THCHHEIE {F
W 2.21? 22mm
11 flflfi'fln }
2 2711 - 2.2??rrm
[H.DB‘BE '- Dflflflh}
2.2“ '- 2.2T4rrm
[1W '- DflflflfiinJ
toms: .. magma]
E m m w
11.10 '- flflm‘n (0.1m: '* 0.01'Ilfln.)
DISCRIMINATION OF CRANKSHAFT BEARING
SELECTION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 2793
1111ML}
M
m
w
Mm
MW
mm...
mm)
Crankshaft: Testing and Inspection
Using a feeler gauge, measure the end play while moving the connecting rod bark and forth.
Standard end play: 0.1 - 0.25 mm (0.004 - 0.010 inch) ^
1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly
2) Remove 2 connecting rod cap bolts. 3) Remove the connecting rod cap and bearing half. 4)
Clean the crank pin and bearing. 5) Place Plastigage across the crank pin. 6) Reinstall the bearing
half and cap, and torque the bolts.
9) If the Plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color
mark (select the color as shown in the next column), and recheck the clearance.
CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 2794
mmulmmn DF GRAHKSHAFI'
CONNECTING ROD MARK LOCATION
10) If the Plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and
NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller
bearings, replace the crankshaft and start over
CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not
scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
DISGRIHIHATIUH OF BRAHHfiHAFT
1.514 - 1.51?mm
1.511 .- 1.514111"
ELM" muses - flflfififih]
LED-E - 1.511mm
{mum - anagram.)
1,505 - 1.505mm
{11.0593 - n.n594In.}
1.5M - 1.50511m
[DflfiEH '- D.Dfi§3in]
DISCRIMINATION OF CRANKSHAFT
11) Selection
1) To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing
halves. 2) Clean each main journal and bearing half with a clean shop tower. 3) Place one strip of
Plastigage across each main journal. 4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque 49.00 Nm (5.0 kgf.m, 36.16 ft. lbs.) + 90° 19.60 Nm (2.0 kgf.m, 14.46 ft. lbs.)+
120° 29.40 - 31.36 Nm (3.0 - 3.2 kgf.m, 21.70 - 23.14 ft. lbs.)
W a l d - I ' m __
om - unflinm mm - nmm;
5) Remove the cap and bearing again, and measure the widest part of the Plastigage.
6) If the Plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color
mark (select the color as shown in the next column), and recheck the clearance.
CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance.
7) If the Plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and
NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller
bearings, replace the crankshaft and start over.
CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust do not
scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
Crankshaft bore mark location Letters have been stamped on the block as a mark for the size of
each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose
the correct bearings.
— — m
13.500 -' 73.5mm
[2.“37 - 2.393B'l'l.)
H.505 - 73.51211'Im
[2.8939 .. 2.594%.)
33.512 33.5‘tflmrn
{2.5942 .. 2.3%.}
DISCRIHIHA'I'IDH DF EHAHKEHAFI'
(2.7145: 2.?147h.)
55.912 - fljllamm
{2.7142 - 2.71431.)
DISCRIMINATION OF CRANKSHAFT
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 2798
THE-“HESS flF
BEARING
2.2T? - 2.2Mn1n1
[5.5555 - 5.555551.)
2.214 - 2.2??rm1
[5.5595 '- 0.0Elfi‘l1.}
2.2T1 *- 2.2T4rrl'n
[5.5594 '- 5.552551}
2.255 - 2.221ITI'I'I
2.255 — 2255111111
[0.0592 * fiflflflfiln-)
play
11.111 - 5.25m (0.55:5 ~ 5.0111111.)
PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING)
SELECTION
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with
a screwdriver. Standard end play 0.10 - 0.28 mm (0.0039 - 0.0110 inch) If the end play is greater
than maximum, replace the thrust bearings as a set. Thrust bearing thickness 2.41 - 2.45 mm
(0.0949 - 0.0964 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 2799
mm m m : 55.94: - mm
(2.114: ~ 2.11m.1
can“: ph my : mm - 54m
[1153: - 2.1mm]
Using a micrometer, measure the diameter of each main journal and crank pin. Main journal
diameter: 68.942 - 68.960 mm (2.7142 - 2.7149 inch) Crank pin diameter: 54.954 - 54.972 mm
(2.1635 - 2.1642 inch)
CONNECTING RODS
1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at
disassembly match. When a new connecting rod is
installed, make sure that the notches for holding the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or
a severely rough surface of the inside diameter of
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is
close to the repair limit, correct the rod by a press.
Any connecting rod that has been severely bent or distorted should be replaced. Allowable bend of
connecting rod 0.05 mm/100 mm (0.0020 inch/3.94 inch) or less Allowable twist of connecting rod:
0.1 mm/100 mm (0.0039 inch/3.94 inch) or less
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer -
Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Piston
Outer diameter
................................................................................................................................................... 91.97
- 92.00 mm (3.6209 - 3.6220 inch) Cylinder clearance
................................................................................................................................................. 0.02 -
0.04 mm (0.0008 - 0.0016 inch) Ring groove width
Piston ring
Side clearance
No. 1 ring
................................................................................................................................................ 0.04 -
0.078 mm (0.0016 - 0.0031 inch) Limit ................................................................................................
...................................................................................... 0.1 mm (0.004 inch) No. 2 ring
.................................................................................................................................................. 0.03 -
0.07 mm (0.0012 - 0.0027 inch) Limit ..................................................................................................
.................................................................................... 0.1 mm (0.004 inch) Oil ring
...................................................................................................................................................... 0.06
- 0.15 mm (0.0024 - 0.0059 inch) Limit ................................................................................................
...................................................................................... 0.2 mm (0.008 inch)
End gap
No. 1 ring
.................................................................................................................................................. 0.17 -
0.32 mm (0.0067 - 0.0126 inch) Limit ..................................................................................................
.................................................................................. 0.6 mm (0.0236 inch) No. 2 ring
.................................................................................................................................................. 0.32 -
0.47 mm (0.0126 - 0.0185 inch) Limit ..................................................................................................
.................................................................................. 0.7 mm (0.0275 inch) Oil ring
...................................................................................................................................................... 0.20
- 0.70 mm (0.0078 - 0.0275 inch) Limit ................................................................................................
.................................................................................... 0.8 mm (0.0315 inch)
Pin
Outer diameter
......................................................................................................................................... 23.001 -
23.006 mm (0.9055 - 0.9057 inch) Hole inner diameter
................................................................................................................................. 23.016 - 23.021
mm (0.9061 - 0.9063 inch) Hole clearance
................................................................................................................................................. 0.01 -
0.02 mm (0.0039 - 0.0078 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Piston
Piston ring
Side clearance
No. 1 ring
................................................................................................................................................ 0.04 -
0.078 mm (0.0016 - 0.0031 inch) Limit ................................................................................................
...................................................................................... 0.1 mm (0.004 inch) No. 2 ring
.................................................................................................................................................. 0.03 -
0.07 mm (0.0012 - 0.0027 inch) Limit ..................................................................................................
.................................................................................... 0.1 mm (0.004 inch) Oil ring
...................................................................................................................................................... 0.06
- 0.15 mm (0.0024 - 0.0059 inch) Limit ................................................................................................
...................................................................................... 0.2 mm (0.008 inch)
End gap
No. 1 ring
.................................................................................................................................................. 0.17 -
0.32 mm (0.0067 - 0.0126 inch) Limit ..................................................................................................
.................................................................................. 0.6 mm (0.0236 inch) No. 2 ring
.................................................................................................................................................. 0.32 -
0.47 mm (0.0126 - 0.0185 inch) Limit ..................................................................................................
.................................................................................. 0.7 mm (0.0275 inch) Oil ring
...................................................................................................................................................... 0.20
- 0.70 mm (0.0078 - 0.0275 inch) Limit ................................................................................................
.................................................................................... 0.8 mm (0.0315 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
Intake ...................................................................................................................................................
.................. 0.10 - 0.30 mm (0.0039 - 0.0118 inch) Exhaust ...............................................................
................................................................................................... 0.20 - 0.40 mm (0.0079 - 0.0157
inch)
Specification
Intake ...................................................................................................................................................
................. 0.17 - 0.23 mm (0.0067 - 0.0090 inch) Exhaust ................................................................
.................................................................................................. 0.27 - 0.33 mm (0.0106 - 0.0129
inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications > Page 2816
Valve Clearance: Adjustments
NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature: 20°C) and cylinder head is installed on the cylinder block.
1. Remove the engine cover. 2. Remove air cleaner assembly. 3. Remove the surge tank.
a. Disconnect the ignition coil connector and remove the ignition coil. b. Disconnect the breather
hose (A) from the cylinder head cover.
c. Loosen the cylinder head cover bolts and then remove the cover (A) and gasket.
a. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain
cover.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications > Page 2817
HH Ex HAUET
a. Check only the valve indicated as shown. [No. 1 cylinder: TDC/Compression] measure the valve
clearance.
- Using a thickness gauge, measure the clearance between the tappet and the base circle of
camshaft.
- Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting tappet.
Valve clearance Specification Engine coolant temperature: 20°C [68°F] Limit Intake: 0.10 - 0.30
mm (0.0039 - 0.0118 inch) Exhaust: 0.20 - 0.40 mm (0.0079 - 0.0157 inch)
b. Turn the crankshaft pulley one revolution (360") and align the groove with timing mark T of the
lower timing chain cover.
a. Set the No. 1 cylinder to the TDC/compression. b. Remove the timing chain. c. Remove the
camshaft bearing caps (A).
g. Calculate the thickness of a new tappet so that the valve clearance comes within the specified
value.
h. Select a new tappet with a thickness as close as possible to the calculated value.
NOTE: Shims are available in 41 size increments of 0.015 mm (0.0006 inch) from 3.00 mm (0.118
inch) to 3.600 mm (0.1417 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications > Page 2819
i. Place a new tappet on the cylinder head.
NOTE: Apply engine oil at the selected tappet on the periphery and top surface.
m. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft
sprocket and camshaft sprocket timing marks. n. Recheck the valve clearance.
Valve clearance (Engine coolant temperature: 20°C [68°F]) [Specification] Intake: 0.17 - 0.23 mm
(0.0067 - 0.0090 inch) Exhaust: 0.27 - 0.33 mm (0.0106 - 0.0129 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release
> System Information > Service and Repair
1. Disconnect the fuel pump connector(A). 2. Start the engine and wait until fuel in fuel line is
exhausted. 3. After the engine stalls, turn the ignition switch to OFF position and disconnect the
negative (-) terminal from the battery.
NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel feed hose, otherwise fuel
will spill out.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cylinder Head Bolts >
Component Information > Technical Service Bulletins > Engine - Torque To Yield Bolt Torque Specifications
Cylinder Head Bolts: Technical Service Bulletins Engine - Torque To Yield Bolt Torque
Specifications
Number 09-EM-006
This bulletin is an extension of TSB 02-20-002 to include latest models and guidelines.
DESCRIPTION:
The information outlined in this bulletin provides reuse guidelines and torque specifications for the
cylinder head, connecting rod, and main bearing bolts that must be fastened using the torque-angle
method.
VEHICLES AFFECTED
REQUIRED TOOLS: ^ Torque Wrench (1/4" for small torque and 3/8" for medium torque values)
NOTE:
Commercially available torque angle gauges such as the Snap-On (P/N TA360) can be used as an
aid to determine the angular values.
SERVICE INFORMATION:
^ Always use fresh engine oil to coat the bolt threads and both sides of the washer of a
torque-angle fastener.
^ Follow the loosening and tightening sequence specified in the applicable Shop Manual for the
cylinder head bolts and the main bearing cap bolts.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Cylinder Head Bolts >
Component Information > Technical Service Bulletins > Engine - Torque To Yield Bolt Torque Specifications > Page 2827
F i fi .23
: :Lrfi. 1—1 :fl-:_ 3 I014
Tau 4.6L
Tinhtminu turqua
9.5a - 11.?fiHm[1.fl - 1.2kn1'm. T23 - flfiflhfjtl
Crankshaft pulley -> A/C pulley -> idler pulley -> alternator pulley -> water pump pulley -> P/S
pump pulley -> tensioner pulley. Rotate auto tensioner arm in the counter - clockwise moving auto
tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto
tensioner pulley slowly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Engine Oil
Type .....................................................................................................................................................
.......... API SJ, SL or Above, ILSAC GF-3 or Above Grade
................................................................................................................. SAE 5W-20, SAE 5W-30
(All Temp. Range), SAE 10W-30 [Above 0°F]
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 2847
Temperature range
need all d1 belnre
enlleheled Heeem'nemled EAE may umber
INSPECTION
Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor,
replace the oil.
After warming up the engine and then 5 minutes after the engine stop, oil level should be between
the L and F marks on the dipstick. If low, check for leakage and add oil up to the F mark.
Lubricants that do not have both an SAE grade number and API service classification on the
container should not be used.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 2848
Engine Oil: Service and Repair
CAUTION: -
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
- Exercise caution in order to minimize the length and frequency of contact of your skin to used oil.
Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
- In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. Wait for 5 minutes after loosening the oil filter cap by turning it counterclockwise to drain well the
oil in the oil filter. 2. Remove the oil filler cap. 3. Remove the oil drain plug, and drain the oil into a
container.
a. Disconnect the oil filter cap from oil filter body. b. Remove the oil filter element. c. Check and
clean the oil filter installation surface. d. Check the part number of the new oil filter is as same as
old one. e. Install new oil filter element (A) and two O-rings (B). f.
Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat. Tightening
torque 24.50 Nm (2.5 kgf.m, 18.08 ft. lbs.)
a. Clean and install the oil drain plug with a new gasket.
Tightening torque 34.3 - 44.1 Nm (3.5 - 4.5 kgf.m, 25.3 - 32.5 ft. lbs.)
Capacity Drain and refill W/Oil filter change: 5.9 Liters (6.23 U. S. qts, 5.19 Imp. quarts) W/O Oil
filter change: 5.5 Liters (5.81 U. S. qts, 4.84 Imp. quarts) Oil filter: 0.4 Liters (0.42 U.S. qts, 0.35
Imp. quarts)
6. Start engine and check for oil leaks. 7. Recheck engine oil level.
Temperature range
need all d1 belnre
enlleheled Heeem'nemled EAE may umber
NOTE: For best performance and maximum protection of all types of operation, select only those
lubricants which: -
Lubricants that do not have both an SAE grade number and API service classification on the
container should not be used.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Service and Repair
Oil Filter: Service and Repair
CAUTION: -
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
- Exercise caution in order to minimize the length and frequency of contact of your skin to used oil.
Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
- In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. Wait for 5 minutes after loosening the oil filter cap by turning it counterclockwise to drain well the
oil in the oil filter. 2. Remove the oil filler cap. 3. Remove the oil drain plug, and drain the oil into a
container.
a. Disconnect the oil filter cap from oil filter body. b. Remove the oil filter element. c. Check and
clean the oil filter installation surface. d. Check the part number of the new oil filter is as same as
old one. e. Install new oil filter element (A) and two O-rings (B). f.
Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat. Tightening
torque 24.50 Nm (2.5 kgf.m, 18.08 ft. lbs.)
a. Clean and install the oil drain plug with a new gasket.
Tightening torque 34.3 - 44.1 Nm (3.5 - 4.5 kgf.m, 25.3 - 32.5 ft. lbs.)
Capacity Drain and refill W/Oil filter change: 5.9 Liters (6.23 U. S. qts, 5.19 Imp. quarts) W/O Oil
filter change: 5.5 Liters (5.81 U. S. qts, 4.84 Imp. quarts) Oil filter: 0.4 Liters (0.42 U.S. qts, 0.35
Imp. quarts)
6. Start engine and check for oil leaks. 7. Recheck engine oil level.
Temperature range
need all d1 belnre
enlleheled Heeem'nemled EAE may umber
NOTE: For best performance and maximum protection of all types of operation, select only those
lubricants which: -
Lubricants that do not have both an SAE grade number and API service classification on the
container should not be used.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine >
Component Information > Service and Repair > Page 2854
22mm Hex, 88mm with 15 Flats Applicable to 2006 Hyundai Sonata, Santa Fe and Azerra (V6)
Made of Aluminum Made in the U.S.A.
REMOVAL
1. Loosen the oil filter cap by turning it counterclockwise to drain well the oil in the oil filter. 2.
Remove surge tank and intake manifold. 3. Disconnect oil pressure switch connector. 4. Drain the
engine coolant. 5. Disconnect water hoses from ETC. 6. Remove water temperature control
assembly. 7. Disconnect water vent hose (A).
INSTALLATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Housing >
Component Information > Service and Repair > Page 2858
— I — H g — I — F — F
Tightening turqua
9.30 ~11JEHrn {1.1: ~ 1.2km.m. T23 - Bfifillafjt}
nu turqul
i3} '- 11.7lnt1n - 1 m T1! '- emu
1. Install oil filter body (A) and new O-rings.
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
NOTE: -
2. Install oil filter body cover (A) and new gasket on the oil filter body.
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
4. Install water temperature control assembly. 5. Connect water hoses on the ETC. 6. Connect oil
pressure switch connector. 7. Install intake manifold and surge tank. 8. Fill with engine coolant. 9.
Start engine and check for leaks.
— — I — - , — I — - - ' — I - — - _
Tightnnhg 'ifififi' _
9.3-1} H 11 .TBNI'I'I {1J3 "' 11ml". TEE "' B.EBIH.fi}
Installation Sequence
1' . --.
IFT EH'Ifll'HEEEUHE
"il' '
. in!
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions
.
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.
Oil Pressure Sender: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2867
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2870
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2871
l
l
P
I
n.
u
n
u
35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2872
fi
1...:
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2873
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2875
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2876
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2877
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2878
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2879
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2880
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Diagram Information and Instructions > Page 2881
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Diagrams > Page 2882
INSPECTION
1. Check the continuity between the terminal and the body with an ohmmeter.
2. Check the continuity between the terminal and the body when the fine wire is pushed.
If there is continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch
is operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Testing and Inspection
1. Disconnect the connector (A) from the warning switch and ground the terminal on the wire
harness side connector.
2. Turn the ignition switch ON. Check that the warning lamp lights up. If the warning lamp doesn't
light, test the bulb or inspect the wire harness.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Temperature Sensor/Switch: Customer Interest Engine Controls - Oil Temperature Sensor Oil
Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
^ Torque Wrench
^ Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil
Temperature Sensor/Switch: > 09-EM-005 > Jul > 09 > Engine Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor/Switch: All Technical Service Bulletins Engine Controls - Oil Temperature
Sensor Oil Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
^ Torque Wrench
^ Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > Page 2905
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Intake Manifold
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2. Remove air cleaner upper cover (D) and intake hose (c).
INSTALLATION
Tightening torque 18.62 - 23.52 Nm (1.9 - 2.4 kgf.m, 13.74 - 17.36 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 6.86 - 10.78 Nm (0.7 - 1.1 kgf.m, 5.06 - 7.96 ft. lbs.)
Tightening torque 27.44 - 31.36 Nm (2.8 - 3.2 kgf.m, 20.25 - 23.14 ft. lbs.)
Tightening torque 15.68 - 25.48 Nm (1.6 - 2.6 kgf.m, 11.57 - 18.80 ft. lbs.)
1. Disconnect the connector (A) from the warning switch and ground the terminal on the wire
harness side connector.
2. Turn the ignition switch ON. Check that the warning lamp lights up. If the warning lamp doesn't
light, test the bulb or inspect the wire harness.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions
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Oil Pressure Sender: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2924
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2927
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2928
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2929
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2930
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2932
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2933
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2934
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2935
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2936
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2937
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2938
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Diagrams > Page 2939
INSPECTION
1. Check the continuity between the terminal and the body with an ohmmeter.
2. Check the continuity between the terminal and the body when the fine wire is pushed.
If there is continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch
is operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > Customer Interest: > 09-EM-005 > Jul > 09
> Engine Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor/Switch: Customer Interest Engine Controls - Oil Temperature Sensor Oil
Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
^ Torque Wrench
^ Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
09-EM-005 > Jul > 09 > Engine Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor/Switch: All Technical Service Bulletins Engine Controls - Oil Temperature
Sensor Oil Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
^ Torque Wrench
^ Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil
Temperature Sensor/Switch: > 09-AT-016 > Aug > 09 > A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh Engagement
Transmission Speed Sensor: All Technical Service Bulletins A/T - MIL ON/DTC's Set/Fail Safe
Mode/Harsh Engagement
Group TRANSAXLE
Number 09-AT-016
DESCRIPTION:
NOTE:
This TSB updates TSB 07-40-016 to add repair information (Step 6).
An improperly functioning input speed sensor or output speed sensor may result in the following
conditions:
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IMT— EHTDURAGE 3.8L EUGE- AEERA 3.3L 8‘. 3.3L
PARTS INFORMATION
SERVICE PROCEDURE:
1. Using a GDS, check for DTCs in both the "Engine" and "Automatic Transaxle" menus. Record
the DTC and description.
^ Vehicle
^ "Input speed sensor" and "output speed sensor". Drive the vehicle and monitor the input and
output speed sensors. If the sensors show:
^ No output, go to Step 3
3. Check the wiring harness visually for an open circuit or short circuit to ground. Check for a
pinched harness at the PCM/TCM attachment bolts.
4. Disconnect the connectors at the input and output speed sensor and PCM/TCM. Check for bent
pins or pins not fully inserted into the connector.
5. If a harness open/short is found, repair or replace the ECM control harness between the
PCM/TCM and transaxle and go to Step 8. If not, go to Step 6.
6. P0722 ONLY: For 2006~ Sonata, 2007~ Santa Fe, 2007~ Entourage and 2006~ Azera vehicles,
check the ground bolt at the location shown. Confirm the threads are clean and the bolt is tight.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil
Temperature Sensor/Switch: > 09-AT-016 > Aug > 09 > A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh Engagement >
Page 2961
7. If the ground bolts are clean and tight, follow the repair procedure shown above.
8. Drive the vehicle for two key-on to key-off driving cycles. If the codes:
9. Exchange a PCM or TCM from a similar year and model vehicle (excluding vehicles with
immobilizer). If the codes:
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil
Temperature Sensor/Switch: > 09-AT-016 > Aug > 09 > A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh Engagement >
Page 2967
-"
Z'U'DE'" SUNATA 2.4L E 3.3L
4}
.j-H
mg
17'
|_G14
IMT— EHTDURAGE 3.8L EUGE- AEERA 3.3L 8‘. 3.3L
PARTS INFORMATION
SERVICE PROCEDURE:
1. Using a GDS, check for DTCs in both the "Engine" and "Automatic Transaxle" menus. Record
the DTC and description.
^ Vehicle
^ "Input speed sensor" and "output speed sensor". Drive the vehicle and monitor the input and
output speed sensors. If the sensors show:
^ No output, go to Step 3
3. Check the wiring harness visually for an open circuit or short circuit to ground. Check for a
pinched harness at the PCM/TCM attachment bolts.
4. Disconnect the connectors at the input and output speed sensor and PCM/TCM. Check for bent
pins or pins not fully inserted into the connector.
5. If a harness open/short is found, repair or replace the ECM control harness between the
PCM/TCM and transaxle and go to Step 8. If not, go to Step 6.
6. P0722 ONLY: For 2006~ Sonata, 2007~ Santa Fe, 2007~ Entourage and 2006~ Azera vehicles,
check the ground bolt at the location shown. Confirm the threads are clean and the bolt is tight.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil
Temperature Sensor/Switch: > 09-AT-016 > Aug > 09 > A/T - MIL ON/DTC's Set/Fail Safe Mode/Harsh Engagement >
Page 2968
7. If the ground bolts are clean and tight, follow the repair procedure shown above.
8. Drive the vehicle for two key-on to key-off driving cycles. If the codes:
9. Exchange a PCM or TCM from a similar year and model vehicle (excluding vehicles with
immobilizer). If the codes:
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Technical Service Bulletins > Page 2969
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Number 10-EM-006
Subject 3.3L & 3.8L TIMING CHAIN TENSIONER - REVISED SERVICE PROCEDURE AND
UPDATED WARRANTY INFORMATION
This TSB supersedes TSB# 08-EM-001-1 to include a revised service procedure and updated
warranty claim submission information.
DESCRIPTION:
For the applicable vehicles equipped with 3.3L and 3.8L V6 engines listed below, this bulletin
outlines the revised service procedure to improve serviceability for the removal and replacement of
both LH/RH timing chain tensioners. The new procedure does not require that the engine be
removed from the vehicle. Accordingly, the updated warranty information has been included.
^ 2007-2008MY Entourage
SERVICE PROCEDURE:
IMPORTANT:
A customer description of start-up engine sound must be documented on the repair order for any
warranty diagnosis and repair. Certain mechanical sounds occurring briefly during initial engine
start-up may be due to prolonged engine shutdown or long-term storage, and may be considered
normal.
Prior to engine disassembly, the customer description and severity of the condition must be
confirmed:
^ Inspect the engine oil level, oil quality, and oil filter service duration.
^ Start the engine and once the engine has reached full operating temperature, turn the engine off
for 10 minutes.
New
^ Listen for any chain type noise that may occur briefly for several seconds immediately upon
engine start-up.
NOTE:
If any start-up noise is observed, then restart engine after 10 minutes and listen to the specific area
shown below with an electronic stethoscope (or equivalent). Repeat this several more times to
confirm the source point of the brief engine start-up sound before continuing on to the service
procedure.
NOTE:
If there are no brief engine start-up sounds after repeated 10 minute shutdown attempts, then do
not perform the Service Procedure described in this TSB. The engine is operating normally. Submit
a Warranty claim for actual time/straight time for inspection only.
1. Record radio station presets and then disconnect the battery ground cable.
2. Remove both front wheels. (Chalk "L" or "R" on corresponding wheel as reference.)
3. Remove the engine side cover at the right front wheel well.
5. Drain engine oil and remove the fastening bolts from the lower oil pan assembly.
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9. Disconnect the intake hose from the throttle body and disconnect the connector to the Mass
Airflow Sensor (MAF).
10. Remove the entire intake hose, MAF, and the upper air cleaner housing in one piece. Place on
a clean and safe area of workbench.
11. Disconnect PCM connectors and remove lower air cleaner housing from vehicle.
12. Disconnect the related connectors and remove the intake surge tank (upper plenum) with the
throttle body.
13. Block the intake ports by placing a protective cover (such as a long strip of duct tape) over the
open ports of the lower intake plenum.
14. Disconnect all related connectors, and remove the ignition coil assemblies.
Support the transmission case with floor jack underneath and remove 4 bolts from the LH upper
mounting bracket of the automatic transmission (as shown above).
NOTE:
To prevent possible damage, use wooden blocks or equivalent between the floor jack lift cup and
the transmission.
17. Sonata and Azera ONLY: Remove the upper radiator hose and then pivot the LH (driver's) side
of the engine down by lowering the floor jack slowly.
18. Sonata, Azera, and Entourage ONLY: Remove the engine coolant reservoir.
19. All models (except Entourage): Disconnect the ground strap from the RH (passenger side) strut
tower.
20. Support the RH of the engine slightly with floor jack underneath the lower oil pan assembly.
NOTE:
To prevent possible damage, use wooden blocks or equivalent between the floor jack lift cup and
the lower oil pan assembly.
21. Remove the RH upper engine mount and bracket of the engine.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page 2984
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23. Sonata and Azera ONLY: Lift the engine until the RH upper mounting deck of engine is level
with the corner of the RH strut tower.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page 2985
3'
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24. Loosen the water pump pulley bolts a few turns each.
29. Release hose clamp to disconnect the center galley coolant hose (as shown above).
NOTE:
When prying loose sealed parts, do not allow the prying tool to scrape or bend the flat sealing
surfaces. Pry at designated external pry points or use suitable tool specified in Shop Manual.
31. Remove the front main oil seal from the timing chain cover.
NOTE:
Carefully use flat scraper or fine wire brush to remove residue without damaging the flat surface.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page 2986
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34. Install new rubber 0-ring and gaskets to the front and back sealing recesses of the timing chain
cover (as shown above).
NOTE:
Once the chain position and guides are secure, remove the pull pin from the new tensioners.
36. Thoroughly wipe clean and dry all the sealing surfaces using a lint-free shop towel.
37. Apply thin bead of liquid gasket to the timing chain cover sealing surfaces of the block, cylinder
head, lower crankcase, and timing chain cover (as shown above).
NOTE:
Use Genuine Hyundai Gray RTV (P/N 00232-19039) or equivalent. Once the liquid gasket is
applied to the sealing surfaces, be sure to assemble the parts within 5 minutes to prevent
premature drying of the liquid gasket.
38. Carefully locate the timing chain cover into position and then attach to the engine.
39. Reinstall the center galley coolant hose and hose clamp.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page 2987
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40. Tighten all timing chain cover fasteners to specifications.
41. Apply a thin bead of liquid gasket and reinstall lower oil pan assembly.
42. Install new front main oil seal (as shown above).
NOTE:
NOTE:
When reattaching the LH upper mounting bracket to the transmission case hand-tighten all 4 bolts
to snug and then final torque to specification.
NOTE:
Before reinstalling both valve covers, remove any old liquid gasket residue at the top surfaces
between the timing cover and the cylinder heads. Reapply liquid gasket to fill the seam points on
the top surface between the timing cover and the cylinder head as shown (there are 2 seam points
for each cylinder bank).
NOTE:
Use a suitable tool to properly allow the cooling system to eliminate the remaining air while the
engine is idling.
NOTE:
Reset clock, radio presets, and (if equipped) FATC setting to display °F instead of °C for
temperature.
PARTS INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page 2989
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WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Page 2990
Timing Chain: Testing and Inspection
INSPECTION
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage.
Replace as necessary. 2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or
damage. Replace as necessary 3. Check that the tensioner piston moves smoothly when the
ratchet pawl is released with thin rod.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of these
flaws are evident, replace the belt.
NOTE: -
- Do not allow the timing belt to come into contact with oil, water and steam.
3. Inspect the idler for easy and smooth rotation and check for play or noise.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle
Timing Chain: Service and Repair With Engine In Vehicle
"The content of this article/image reflects the changes identified in TSB - 08-EM-001-1."
DESCRIPTION:
For the applicable vehicles equipped with 3.3L and 3.8L V6 engines listed below, this bulletin
outlines the revised service procedure to improve serviceability for the removal and replacement of
both LH/RH timing chain tensioners. The new procedure does not require that the engine be
removed from the vehicle. Accordingly, the updated warranty information has been included.
APPLICABLE VEHICLES: -
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TIMING SYSTEM
COMPONENT
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 2994
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COMPONENT
REMOVAL
Engine removal is required for this procedure.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 2995
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1. Remove the drive belt (A).
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5. Remove drive belt idler (A).
DISASSEMBLY
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 2997
1. Remove cylinder head cover.
b. Disconnect RH ignition coil connector (A), condenser connector (B) and remove wiring bracket
(C)
c. Remove LH, RH ignition coil. d. Remove LH, RH cylinder head cover (A).
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a. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain
cover.
b. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head
surface as shown in the illustration.
Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan, and cut off
applied sealer and removed lower oil pan.
NOTE: Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
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‘5“
5. Remove the timing chain cover (A).
NOTE: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing
chain cover
8. Remove RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3000
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9. Remove RH timing chain guide (A).
12. Remove oil pump chain guide (A). 13. Remove RH timing chain.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3001
.J «5-- -" D
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14. Remove oil pump chain sprocket (A) and oil pump chain (B).
17. Remove LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B). 18. Remove
LH timing chain.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3002
19. Remove LH timing chain guide (A).
INSPECTION
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage.
Replace as necessary. 2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or
damage. Replace as necessary 3. Check that the tensioner piston moves smoothly when the
ratchet pawl is released with thin rod.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of these
flaws are evident, replace the belt.
NOTE: -
- Do not allow the timing belt to come into contact with oil, water and steam.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3003
3. Inspect the idler for easy and smooth rotation and check for play or noise.
REASSEMBLY
1. The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a
result of this, the piston of No. 1 cylinder is
TigManning turqui .
19.60 - 2 4 m g- mm. “.1? ~ 1MB“)
Tightaninu turqul
9.3a - 11.1mm.u - 1mm. 7.23 - imam
4. Install LH timing chain guide (A).
Tightening torque 19.60 - 24.50 Nm (2.0 - 2.5 kgf.m, 14.17 - 18.08 ft. lbs.)
LH Timing Chain
To install the timing chain with no slack between each shaft (cam, crank), follow this procedure.
Crankshaft sprocket (A) -> Timing chain guide (B) ->Exhaust camshaft sprocket (c) -> Intake
camshaft sprocket (D). The timing mark of each sprockets should be matched with timing mark
(color link) of timing chain at installing timing chain.
Tightening torque 18.62 - 21.56 Nm (1.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3005
-—I— . - ' — | — . . - — _ — I — . -
Tlghtuhui'fihuH-qua
9H - 11.1'BHmflJJ ~1Mm. 1.23 - m m
Tightening turqua
18.62 - 21.55Hm[1.9 - 2.2kgtrn. 13.?4- - 15.91I1f.ft}
8. Install LH cam-to-cam guide (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
10. Install oil pump chain (B) and oil pump sprocket (A).
Tightening torque 18.62 - 21.56 Nm (1.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.)
To install the timing chain with no slack between each shaft (cam, crank), follow this procedure.
Crankshaft sprocket (A) -> Intake camshaft sprocket (B) -> Exhaust camshaft sprocket (C). The
timing mark of each sprockets should be matched with timing mark (color link) of timing chain at
installing timing chain.
R
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
.
Information > Service and Repair > With Engine In Vehicle > Page 3006
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Tightening torque 19.60 - 24.50 Nm (2.0 - 2.5 kgf.m, 14.17 - 18.08 ft. lbs.)
m m
nan-11.7mm-m- 1.2mm.1'23q
14. Install RH timing chain auto tensioner (A) and pull out the pins of hydraulic tensioners (LH &
RH)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1 .0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3008
fight-ulna III-qua
9.50 - 11.7mm - 1mm
m
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m
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mm~11.mw.u~1m?m 3mm
17. Install oil pump chain tensioner assembly (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
19. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm
the timing mark.
a. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and
lower oil pan) must be free of engine oil and
ETC.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3009
Tightening turqua
a {171: 13.62 - 21.55Mmt13 +- 22kgf.n1,13.?4 — 15.9'flbf.ft}
I: {II}: 9.51} - 11.?Ellllml1.fl ..1 .Ekfllm. 123 '- flfifllbffi]
D {1}: Ell} - Eflfiflflrnfifl -- T.fl:fl.m.43.dfl - fiflfiflllffi}
The part must be assembled within 5 minutes after sealant was applied. Bead width: 2.5 mm (0.1
inch)
The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied
without discontinuity. Bead width: 2.5 mm (0.1 inch)
d. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a
reference in order to assemble the timing chain
cover to be in exact position. Tightening torque B (17): 18.62 - 21.56 Nm (0.9 - 2.2 kgf.m, 13.74 -
15.91 ft. lbs.) C (4): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.) D (1): 58.80 - 68.80 Nm
(6.0 - 7.0 kgf.m, 43.40 - 50.63 ft. lbs.) E (1): 58.80 - 68.80 Nm (6.0 - 7.0 kgf.m, 43.40 - 50.63 ft. lbs.)
F (2): 24.50 - 26.46 Nm (2.5 - 2.7 kgf.m, 18.08 - 19.53 ft. lbs.) G (4): 21.56 - 23.52 Nm (2.2 - 2.4
kgf.m, 15.91 - 17.36 ft. lbs.) H (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3010
I (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.) J (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m,
7.23 - 8.68 ft. lbs.)
e. The firing and/or blow out test should not be performed within 30 minutes after the timing chain
cover was assembled.
21. Using SST (09231-3C100), install timing chain cover oil seal.
a. Using a gasket scraper, remove all the old packing material from the gasket surfaces. b. Before
assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan.
The part must be assembled within 5 minutes after the sealant was applied. Bead width: 2.5 mm
(0.1 inch). But marked area (*) to be 5.0 mm (0.2 inch)
CAUTION: -
- Remove harmful foreign matters on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
- To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3011
Tlgflln'mg hm
9.80 - “smut-[1.1: - Elfin. 123 - flfllhflt]
Tlnhtnnlna tmqut
254.2 - 3411mm - 31.Wm. 1H.”
- Emu}
Uniformly tighten the bolts in several passes. Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m,
7.23 - 8.68 ft. lbs.)
Tightening torque 284.2 - 303.8 Nm (29.0 - 31.0 kgf.m, 209.76 - 224.22 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3012
Tightening turqm
9.5:] - 11.?5Hn1[1.fl ~ 1.2kgfm. T23 ~ Bfifllbfjt}
24. Install cylinder head cover.
a. The hardening sealant located on the upper area between timing chain cover and cylinder head
should be removed before assembling cylinder
head cover.
c. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head
cover was assembled.
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
f. Connect RH ignition coil connector (A), condenser connector (B) and install wiring bracket (C).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3013
Tighhnhg turqua
134 - Bfitflmtflfl - LWm, 513 .. ?.23Ihl.fi}
Tighhrflna tun-Int
95.04 -- finfiflmfifi - 1fl2kgfm. TEES ~ fiffilbffi]
1TH: - 21.5mm - 2.2kmm. 13.112 - 15.31Ibfm
til 1
g. Install connector bracket (A) from LH cylinder head cover.
INSTALLATION
Tightening torque 7.84 - 9.80 Nm (0.8 - 1.0 kgf.m, 5.78 - 7.23 ft. lbs.)
Tightening torque 96.04 - 99.96 Nm (9.8 - 10.2 kgf.m, 70.85 - 73.74 ft. lbs.) 17.64 - 21.56 Nm (1.8 -
2.2 kgf.m, 13.02 - 15.91 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > With Engine In Vehicle > Page 3014
fighhfii—flg turd-u:
52.92 - fill”mtfiA - Emulm, 351E -- 4231mm]
4. Install drive belt idler (A).
Tightening torque 52.92 - 57.82 Nm (5.4 - 5.9 kgf.m, 39.06 - 42.67 ft. lbs.)
Crankshaft pulley -> A/C pulley -> idler pulley -> alternator pulley -> water pump pulley -> P/S
pump pulley -> tensioner pulley. Rotate auto tensioner arm in the counter - clockwise moving auto
tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto
tensioner pulley slowly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc.
Timing Chain Tensioner: Technical Service Bulletins Engine - Revised Timing Chain Tensioner
Service Proc.
Number 10-EM-006
Subject 3.3L & 3.8L TIMING CHAIN TENSIONER - REVISED SERVICE PROCEDURE AND
UPDATED WARRANTY INFORMATION
This TSB supersedes TSB# 08-EM-001-1 to include a revised service procedure and updated
warranty claim submission information.
DESCRIPTION:
For the applicable vehicles equipped with 3.3L and 3.8L V6 engines listed below, this bulletin
outlines the revised service procedure to improve serviceability for the removal and replacement of
both LH/RH timing chain tensioners. The new procedure does not require that the engine be
removed from the vehicle. Accordingly, the updated warranty information has been included.
^ 2007-2008MY Entourage
SERVICE PROCEDURE:
IMPORTANT:
A customer description of start-up engine sound must be documented on the repair order for any
warranty diagnosis and repair. Certain mechanical sounds occurring briefly during initial engine
start-up may be due to prolonged engine shutdown or long-term storage, and may be considered
normal.
Prior to engine disassembly, the customer description and severity of the condition must be
confirmed:
^ Inspect the engine oil level, oil quality, and oil filter service duration.
^ Start the engine and once the engine has reached full operating temperature, turn the engine off
for 10 minutes.
New
^ Listen for any chain type noise that may occur briefly for several seconds immediately upon
engine start-up.
NOTE:
If any start-up noise is observed, then restart engine after 10 minutes and listen to the specific area
shown below with an electronic stethoscope (or equivalent). Repeat this several more times to
confirm the source point of the brief engine start-up sound before continuing on to the service
procedure.
NOTE:
If there are no brief engine start-up sounds after repeated 10 minute shutdown attempts, then do
not perform the Service Procedure described in this TSB. The engine is operating normally. Submit
a Warranty claim for actual time/straight time for inspection only.
1. Record radio station presets and then disconnect the battery ground cable.
2. Remove both front wheels. (Chalk "L" or "R" on corresponding wheel as reference.)
3. Remove the engine side cover at the right front wheel well.
5. Drain engine oil and remove the fastening bolts from the lower oil pan assembly.
7. Drain, disconnect, and remove the hose connection between the power steering reservoir and
the power steering pump (as shown above).
8. Remove the upper engine cover.
9. Disconnect the intake hose from the throttle body and disconnect the connector to the Mass
Airflow Sensor (MAF).
10. Remove the entire intake hose, MAF, and the upper air cleaner housing in one piece. Place on
a clean and safe area of workbench.
11. Disconnect PCM connectors and remove lower air cleaner housing from vehicle.
12. Disconnect the related connectors and remove the intake surge tank (upper plenum) with the
throttle body.
13. Block the intake ports by placing a protective cover (such as a long strip of duct tape) over the
open ports of the lower intake plenum.
14. Disconnect all related connectors, and remove the ignition coil assemblies.
Support the transmission case with floor jack underneath and remove 4 bolts from the LH upper
mounting bracket of the automatic transmission (as shown above).
NOTE:
To prevent possible damage, use wooden blocks or equivalent between the floor jack lift cup and
the transmission.
17. Sonata and Azera ONLY: Remove the upper radiator hose and then pivot the LH (driver's) side
of the engine down by lowering the floor jack slowly.
18. Sonata, Azera, and Entourage ONLY: Remove the engine coolant reservoir.
19. All models (except Entourage): Disconnect the ground strap from the RH (passenger side) strut
tower.
20. Support the RH of the engine slightly with floor jack underneath the lower oil pan assembly.
NOTE:
To prevent possible damage, use wooden blocks or equivalent between the floor jack lift cup and
the lower oil pan assembly.
21. Remove the RH upper engine mount and bracket of the engine.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page
3022
. " . ‘ I.
‘ - ‘ ,
.- - " I- '
I
22. Attach engine support fixture SST (or equivalent) to a hoisting point at the top of the engine to
support the weight of the engine.
23. Sonata and Azera ONLY: Lift the engine until the RH upper mounting deck of engine is level
with the corner of the RH strut tower.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page
3023
‘ 1‘, ,
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RELEASE CLAMP TD
DISCONHECT HOSE ,
"in.
24. Loosen the water pump pulley bolts a few turns each.
29. Release hose clamp to disconnect the center galley coolant hose (as shown above).
NOTE:
When prying loose sealed parts, do not allow the prying tool to scrape or bend the flat sealing
surfaces. Pry at designated external pry points or use suitable tool specified in Shop Manual.
31. Remove the front main oil seal from the timing chain cover.
32. Remove the lower oil pan.
NOTE:
Carefully use flat scraper or fine wire brush to remove residue without damaging the flat surface.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page
3024
. mama am: FOR OUTER 3m: 13.a SEAL: FOR INNER sin: y
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34. Install new rubber 0-ring and gaskets to the front and back sealing recesses of the timing chain
cover (as shown above).
NOTE:
Once the chain position and guides are secure, remove the pull pin from the new tensioners.
36. Thoroughly wipe clean and dry all the sealing surfaces using a lint-free shop towel.
37. Apply thin bead of liquid gasket to the timing chain cover sealing surfaces of the block, cylinder
head, lower crankcase, and timing chain cover (as shown above).
NOTE:
Use Genuine Hyundai Gray RTV (P/N 00232-19039) or equivalent. Once the liquid gasket is
applied to the sealing surfaces, be sure to assemble the parts within 5 minutes to prevent
premature drying of the liquid gasket.
38. Carefully locate the timing chain cover into position and then attach to the engine.
39. Reinstall the center galley coolant hose and hose clamp.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page
3025
. INS-TILL Fflfllfl' HM" SEAL
u —;r-- ‘-
42. Install new front main oil seal (as shown above).
NOTE:
NOTE:
When reattaching the LH upper mounting bracket to the transmission case hand-tighten all 4 bolts
to snug and then final torque to specification.
NOTE:
Before reinstalling both valve covers, remove any old liquid gasket residue at the top surfaces
between the timing cover and the cylinder heads. Reapply liquid gasket to fill the seam points on
the top surface between the timing cover and the cylinder head as shown (there are 2 seam points
for each cylinder bank).
^ Install the valve covers within 5 minutes after applying the liquid gasket.
NOTE:
Use a suitable tool to properly allow the cooling system to eliminate the remaining air while the
engine is idling.
NOTE:
Reset clock, radio presets, and (if equipped) FATC setting to display °F instead of °C for
temperature.
PARTS INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Engine - Revised Timing Chain Tensioner Service Proc. > Page
3027
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24+1fl-3G1IJD
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WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle
"The content of this article/image reflects the changes identified in TSB - 10-EM-006."
DESCRIPTION:
For the applicable vehicles equipped with 3.3L and 3.8L V6 engines listed below, this bulletin
outlines the revised service procedure to improve serviceability for the removal and replacement of
both LH/RH timing chain tensioners. The new procedure does not require that the engine be
removed from the vehicle. Accordingly, the updated warranty information has been included.
APPLICABLE VEHICLES: -
SERVICE PROCEDURE:
IMPORTANT:
A customer complaint and statement related to start-up engine sound must be documented on the
repair order for any warranty diagnosis and repair. Certain mechanical sounds occurring briefly
during initial engine start-up may be due to prolonged engine shutdown or long-term storage, and
may be considered normal.
Prior to engine disassembly, the customer complaint and severity of condition must be confirmed:
- Inspect the engine oil level, oil quality, and oil filter service duration.
- Start the engine and once the engine has reached full operating temperature, turn the engine off
for 10 minutes.
- Listen for any chain type noise that may occur briefly for several seconds immediately upon
engine start-up.
NOTE: If any start-up noise is observed, then restart engine after 10 minutes and listen to the
specific area shown below with an electronic
stethoscope (or equivalent). Repeat this several more times to confirm the source point of the brief
engine start-up sound before continuing on to the service procedure.
NOTE: If there are no brief engine start-up sounds after repeated 10 minute shutdown attempts,
then do not perform the Service Procedure of this
1. Record radio station presets and then disconnect the battery ground cable. 2. Remove both front
wheels. (Chalk L or R on corresponding wheel as reference.) 3. Remove the engine side cover at
the right front wheel well. 4. Remove lower engine cover(s). 5. Drain engine oil and remove the
fastening bolts from the lower oil pan assembly. 6. Drain the engine coolant from the radiator. 7.
Drain, disconnect, and remove the hose connection between the power steering reservoir and the
power steering pump.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3030
fl.”
P5 PUMP INLET
10. Remove the entire intake hose, MAF, and the upper air cleaner housing in one piece. Place on
a clean and safe area of workbench. 11. Disconnect PCM connectors and remove lower air cleaner
housing from vehicle. 12. Disconnect the related connectors and remove the intake surge tank
(upper plenum) with the throttle body. 13. Block the intake ports by placing a protective cover (such
as a long strip of duct tape) over the open ports of the lower intake plenum. 14. Disconnect all
related connectors, and remove the ignition coil assemblies. 15. Remove the LH and RH valve
cover assemblies. 16. Sonata and Azera ONLY: Support the transmission case with floor jack
underneath and remove 4 bolts from the LH upper mounting bracket of
NOTE: To prevent possible damage, use wooden blocks or equivalent between the floor jack lift
cup and the transmission.
17. Sonata and Azera ONLY: Remove the upper radiator hose and then pivot the LH (driver's) side
of the engine down by lowering the floor jack
slowly.
18. Sonata, Azera, and Entourage ONLY: Remove the engine coolant reservoir. 19. All models
(except Entourage): Disconnect the ground strap from the RH (passenger side) strut tower. 20.
Support the RH of the engine slightly with floor jack underneath the lower oil pan assembly.
NOTE: To prevent possible damage, use wooden blocks or equivalent between the floor jack lift
cup and the lower oil pan assembly.
21. Remove the RH upper engine mount and bracket of the engine.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3031
' F .- .—— - .
. VEHICLE snuwu: son-mm 3.3L . .
5., (OTHER HDDELE HAY VARY SLIGHTLY) '
22. Attach engine support fixture SST (or equivalent) to a hoisting point at the top of the engine to
support the weight of the engine.
23. Sonata and Azera ONLY: Lift the engine until the RH upper mounting deck of engine is level
with the corner of the RH strut tower.
24. Loosen the water pump pulley bolts a few turns each.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3032
,IHELEIALSE cLAMP'Tu
DISCDHHEET HflSE
NOTE: When prying loose sealed parts, do not allow the prying tool to scrape or bend the flat
sealing surfaces. Pry at designated external pry points
31. Remove the front main oil seal from the timing chain cover. 32. Remove the lower oil pan. 33.
Clean off old liquid gasket and residue from:
NOTE: Carefully use flat scraper or fine wire brush to remove residue without damaging the flat
surface.
34. Install new rubber o-ring and gaskets to the front and back sealing recesses of the timing chain
cover.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3033
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35. Remove and replace both timing chain tensioners.
NOTE: Once the chain position and guides are secure, remove the pull pin from the new
tensioners.
36. Thoroughly wipe clean and dry all the sealing surfaces using a lint-free shop towel. 37. Apply
thin bead of liquid gasket to the timing chain cover sealing surfaces of the block, cylinder head,
lower crankcase, and also the timing chain
cover.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3034
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NOTE: Once the liquid gasket is applied to the sealing surfaces, be sure to assemble the parts
within 5 minutes to prevent premature drying of the
liquid gasket.
38. Carefully locate the timing chain cover into position and then attach to the engine. 39. Reinstall
the center galley coolant hose and hose clamp. 40. Tighten all timing chain cover fasteners to
specifications. 41. Apply thin bead of liquid gasket and reinstall lower oil pan assembly. 42. Install
new front main oil seal.
NOTE: When reattaching the LH upper mounting bracket to the transmission case, hand-tighten all
4 bolts to snug and then final torque to
specification.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3035
ll
heads. Reapply liquid gasket to fill the seam points on the top surface between the timing cover
and the cylinder head as shown (there are 2 seam points for each cylinder bank).
- Bead width: 0.1 in (2.5 mm) - Install the valve covers within 5 minutes after applying the liquid
gasket.
NOTE: Use a suitable tool to properly allow the cooling system to eliminate the remaining air while
the engine is idling.
NOTE: Reset clock, radio presets, and (if equipped) FATC setting to display —F instead of —C for
temperature.
PARTS IHFDRMATIDH:
CDHPDNEHT
1154 - 21.5:
:13 -. 13.34:: .. 15.91}
TIMING SYSTEM
COMPONENT
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3038
15.511 - m
up .. 11.1; {2.1: - 2.5. 11.11 - 1am}
I {La —1.2. ma — m}
1a.aa — a1.aa
(La -. 12,1334 .. 15.91]
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COMPONENT
REMOVAL
Engine removal is required for this procedure.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3039
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5. Remove drive belt idler (A).
DISASSEMBLY
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3041
1. Remove cylinder head cover.
b. Disconnect RH ignition coil connector (A), condenser connector (B) and remove wiring bracket
(C)
c. Remove LH, RH ignition coil. d. Remove LH, RH cylinder head cover (A).
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a. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain
cover.
b. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head
surface as shown in the illustration.
Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan, and cut off
applied sealer and removed lower oil pan.
NOTE: Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
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5. Remove the timing chain cover (A).
NOTE: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing
chain cover
8. Remove RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3044
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9. Remove RH timing chain guide (A).
12. Remove oil pump chain guide (A). 13. Remove RH timing chain.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3045
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14. Remove oil pump chain sprocket (A) and oil pump chain (B).
17. Remove LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B). 18. Remove
LH timing chain.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3046
19. Remove LH timing chain guide (A).
INSPECTION
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage.
Replace as necessary. 2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or
damage. Replace as necessary 3. Check that the tensioner piston moves smoothly when the
ratchet pawl is released with thin rod.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of these
flaws are evident, replace the belt.
NOTE: -
- Do not allow the timing belt to come into contact with oil, water and steam.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3047
3. Inspect the idler for easy and smooth rotation and check for play or noise.
REASSEMBLY
1. The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a
result of this, the piston of No. 1 cylinder is
TigManning turqui .
19.60 - 2 4 m g- mm. “.1? ~ 1MB“)
Tightaninu turqul
9.3a - 11.1mm.u - 1mm. 7.23 - imam
4. Install LH timing chain guide (A).
Tightening torque 19.60 - 24.50 Nm (2.0 - 2.5 kgf.m, 14.17 - 18.08 ft. lbs.)
LH Timing Chain
To install the timing chain with no slack between each shaft (cam, crank), follow this procedure.
Crankshaft sprocket (A) -> Timing chain guide (B) ->Exhaust camshaft sprocket (c) -> Intake
camshaft sprocket (D). The timing mark of each sprockets should be matched with timing mark
(color link) of timing chain at installing timing chain.
Tightening torque 18.62 - 21.56 Nm (1.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3049
-—I— . - ' — | — . . - — _ — I — . -
Tlghtuhui'fihuH-qua
9H - 11.1'BHmflJJ ~1Mm. 1.23 - m m
Tightening turqua
18.62 - 21.55Hm[1.9 - 2.2kgtrn. 13.?4- - 15.91I1f.ft}
8. Install LH cam-to-cam guide (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
10. Install oil pump chain (B) and oil pump sprocket (A).
Tightening torque 18.62 - 21.56 Nm (1.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.)
To install the timing chain with no slack between each shaft (cam, crank), follow this procedure.
Crankshaft sprocket (A) -> Intake camshaft sprocket (B) -> Exhaust camshaft sprocket (C). The
timing mark of each sprockets should be matched with timing mark (color link) of timing chain at
installing timing chain.
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
.
Component Information > Service and Repair > With Engine In Vehicle > Page 3050
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Tightening torque 19.60 - 24.50 Nm (2.0 - 2.5 kgf.m, 14.17 - 18.08 ft. lbs.)
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14. Install RH timing chain auto tensioner (A) and pull out the pins of hydraulic tensioners (LH &
RH)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1 .0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3052
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9.50 - 11.7mm - 1mm
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17. Install oil pump chain tensioner assembly (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
19. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm
the timing mark.
a. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and
lower oil pan) must be free of engine oil and
ETC.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3053
Tightening turqua
a {171: 13.62 - 21.55Mmt13 +- 22kgf.n1,13.?4 — 15.9'flbf.ft}
I: {II}: 9.51} - 11.?Ellllml1.fl ..1 .Ekfllm. 123 '- flfifllbffi]
D {1}: Ell} - Eflfiflflrnfifl -- T.fl:fl.m.43.dfl - fiflfiflllffi}
The part must be assembled within 5 minutes after sealant was applied. Bead width: 2.5 mm (0.1
inch)
The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied
without discontinuity. Bead width: 2.5 mm (0.1 inch)
d. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a
reference in order to assemble the timing chain
cover to be in exact position. Tightening torque B (17): 18.62 - 21.56 Nm (0.9 - 2.2 kgf.m, 13.74 -
15.91 ft. lbs.) C (4): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.) D (1): 58.80 - 68.80 Nm
(6.0 - 7.0 kgf.m, 43.40 - 50.63 ft. lbs.) E (1): 58.80 - 68.80 Nm (6.0 - 7.0 kgf.m, 43.40 - 50.63 ft. lbs.)
F (2): 24.50 - 26.46 Nm (2.5 - 2.7 kgf.m, 18.08 - 19.53 ft. lbs.) G (4): 21.56 - 23.52 Nm (2.2 - 2.4
kgf.m, 15.91 - 17.36 ft. lbs.) H (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3054
I (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.) J (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m,
7.23 - 8.68 ft. lbs.)
e. The firing and/or blow out test should not be performed within 30 minutes after the timing chain
cover was assembled.
21. Using SST (09231-3C100), install timing chain cover oil seal.
a. Using a gasket scraper, remove all the old packing material from the gasket surfaces. b. Before
assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan.
The part must be assembled within 5 minutes after the sealant was applied. Bead width: 2.5 mm
(0.1 inch). But marked area (*) to be 5.0 mm (0.2 inch)
CAUTION: -
- Remove harmful foreign matters on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
- To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3055
Tlgflln'mg hm
9.80 - “smut-[1.1: - Elfin. 123 - flfllhflt]
Tlnhtnnlna tmqut
254.2 - 3411mm - 31.Wm. 1H.”
- Emu}
Uniformly tighten the bolts in several passes. Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m,
7.23 - 8.68 ft. lbs.)
Tightening torque 284.2 - 303.8 Nm (29.0 - 31.0 kgf.m, 209.76 - 224.22 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3056
Tightening turqm
9.5:] - 11.?5Hn1[1.fl ~ 1.2kgfm. T23 ~ Bfifllbfjt}
24. Install cylinder head cover.
a. The hardening sealant located on the upper area between timing chain cover and cylinder head
should be removed before assembling cylinder
head cover.
c. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head
cover was assembled.
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
f. Connect RH ignition coil connector (A), condenser connector (B) and install wiring bracket (C).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3057
Tighhnhg turqua
134 - Bfitflmtflfl - LWm, 513 .. ?.23Ihl.fi}
Tighhrflna tun-Int
95.04 -- finfiflmfifi - 1fl2kgfm. TEES ~ fiffilbffi]
1TH: - 21.5mm - 2.2kmm. 13.112 - 15.31Ibfm
til 1
g. Install connector bracket (A) from LH cylinder head cover.
INSTALLATION
Tightening torque 7.84 - 9.80 Nm (0.8 - 1.0 kgf.m, 5.78 - 7.23 ft. lbs.)
Tightening torque 96.04 - 99.96 Nm (9.8 - 10.2 kgf.m, 70.85 - 73.74 ft. lbs.) 17.64 - 21.56 Nm (1.8 -
2.2 kgf.m, 13.02 - 15.91 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > With Engine In Vehicle > Page 3058
fighhfii—flg turd-u:
52.92 - fill”mtfiA - Emulm, 351E -- 4231mm]
4. Install drive belt idler (A).
Tightening torque 52.92 - 57.82 Nm (5.4 - 5.9 kgf.m, 39.06 - 42.67 ft. lbs.)
Crankshaft pulley -> A/C pulley -> idler pulley -> alternator pulley -> water pump pulley -> P/S
pump pulley -> tensioner pulley. Rotate auto tensioner arm in the counter - clockwise moving auto
tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto
tensioner pulley slowly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component
Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
LH Timing Chain
RH Timing Chain
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain
at installing timing chain.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Tightening 111111115
5 1121: 15.52 - 21.5511m112 +— 22kgf.n1,13.?4 - 152151.111
1: 1111: 551:1 - 11.111111111111111 - 1.Ekfltm. 2.25 - 5.55111111]
1: 11}: 55.55 - 55.55111111155 - 2-111521112521111 - 55.522115}
E [1}: 55.30 "" fiflflflflrfififl " lflfiflflnfiflfifl "' fiflflfllhffll
Timing Cover
B ............................................................................................................................................... 18.62
- 21.56 Nm (0.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.) C
..................................................................................................................................................... 9.80
- 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.) D
............................................................................................................................................... 58.80 -
68.80 Nm (6.0 - 7.0 kgf.m, 43.40 - 50.63 ft. lbs.) E
............................................................................................................................................... 58.80 -
68.80 Nm (6.0 - 7.0 kgf.m, 43.40 - 50.63 ft. lbs.) F
............................................................................................................................................... 24.50 -
26.46 Nm (2.5 - 2.7 kgf.m, 18.08 - 19.53 ft. lbs.) G
............................................................................................................................................... 21.56 -
23.52 Nm (2.2 - 2.4 kgf.m, 15.91 - 17.36 ft. lbs.) H
.................................................................................................................................................... 9.80
- 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.) I
...................................................................................................................................................... 9.80
- 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.) J
...................................................................................................................................................... 9.80
- 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Engine - CVVT Oil Control Valve
Inspection
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Variable Valve Timing Actuator: Technical Service Bulletins Engine - CVVT Oil Control Valve
Inspection
Group ENGINE
Number 09-EM-002
When diagnosing the Continuously Variable Valve Timing (CVVT) system for rough idling, poor
acceleration, camshaft timing misalignment-related trouble codes, misfire related trouble codes,
and/or other related symptoms, it may be required to inspect the Oil Control Valve (OCV) for proper
operation. Follow the procedure outlined in this bulletin to inspect the OCV. If the OCV operates
normally, then carry out other necessary repairs. Do not replace the OCV if normal operation is
confirmed.
APPLICABLE VEHICLES:
Carry on
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Hun-Inn thl furnish “trill Ind Ihln Vll'lfy' thlt thl flult II turf-did.
NOTE: DD HflTrmllfl HI! OCVHMHM dlmlflab [ha HEM
am: BUFFIJER
{BEE PAGE 1) can RESISTANCE AT am {EDT} I
1. Measure the resistance between the OCV Power and Signal terminals.
2. Check if the OCV operates normally by providing 12V power as shown in the picture above.
IMPORTANT:
Careful attention is necessary to avoid a short circuit when providing the OCV with 12V power.
Spacing between the OCV power and signal terminals is very narrow. Use suitable connections to
prevent shorting of the test power supply.
3. When 12V power is provided to the OCV, the OCV must move forward as shown in the picture
shown above.
NOTE:
4. If the OCV does not move forward, examine if a foreign object like an aluminum chip (C) is
jammed inside the OCV.
^ Blow out the foreign object using compressed air, reinstall the OCV and then verify that the fault
is corrected.
WARRANTY INFORMATION:
Detail
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 3076
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Technical Service Bulletins > Page 3077
DESCRIPTION
Continuously Variable Valve Timing (CVVT system controls valve overlap with forcibly activating
the camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas
(NOx, HC) and improves fuel economy, idle state, torque in low speed and power in high speed.
This system uses engine oil pressure and consists of the two CVVT Oil Control Valve (OCV) in
each bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
SPECIFIGATIHH
“ spawn
mm
DESCRIPTION
Continuously Variable Valve Timing (CVVT system controls valve overlap with forcibly activating
the camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas
(NOx, HC) and improves fuel economy, idle state, torque in low speed and power in high speed.
This system uses engine oil pressure and consists of the two CVVT Oil Control Valve (OCV) in
each bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
Specification
INSTALLATION
CAUTION: If the OCVs are installed incorrectly, the vehicle may be damaged. So when installing
them, be careful its connector color (Components and harness side).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications
Fuel Pressure: Specifications
Standard
Value:.....................................................................................................................................374 -
384 kPa (3.82 - 3.92 kg/sq.cm, 54.3 - 55.8 psi)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 3083
1. PREPARING
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Idle Speed
A/C ON OFF
Natural,N,P-range.................................................................................................................................
.........................................................620 ± 100 rpm D-range...............................................................
.........................................................................................................................................620 ± 100
rpm
A/C ON ON
Natural,N,P-range.................................................................................................................................
.........................................................620 ± 100 rpm D-range...............................................................
...........................................................................................................................................620 ± 100
rpm
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair
1. Disconnect the fuel pump connector(A). 2. Start the engine and wait until fuel in fuel line is
exhausted. 3. After the engine stalls, turn the ignition switch to OFF position and disconnect the
negative (-) terminal from the battery.
NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel feed hose, otherwise fuel
will spill out.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
..............................................................................................................................................................
............................................
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Timing > Number One Cylinder > Component Information > Locations
©®®
Frunt uf 1'ul'rmlnllr';
NOTE: when removing the ignition coil connector, pull the lock pin(A) and push the clip(B).
CAUTION: Be careful that no contaminates enter through the spark plug holes.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Ignition Cable > Component Information > Testing and Inspection > Page 3103
IHEFEEHUH HF R E M
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tun rl'fl'l
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4. Inspect the electrodes (A) and ceramic insulator (B).
NGK .....................................................................................................................................................
.................................................................. IFR5G-11
Gap ......................................................................................................................................................
................................ 1.0-1.1 mm (0.039-0.043 inch)
Torque .................................................................................................................................................
............................................. 20-30 Nm (15-22 lb.ft)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3107
Spark Plug: Application and ID
NGK .....................................................................................................................................................
.................................................................. IFR5G-11
Gap ......................................................................................................................................................
................................ 1.0-1.1 mm (0.039-0.043 inch)
Torque .................................................................................................................................................
............................................. 20-30 Nm (15-22 lb.ft)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3108
Spark Plug: Testing and Inspection
NOTE: when removing the ignition coil connector, pull the lock pin(A) and push the clip(B).
CAUTION: Be careful that no contaminates enter through the spark plug holes.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3109
IHEFEEHUH HF R E M
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tun rl'fl'l
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4. Inspect the electrodes (A) and ceramic insulator (B).
ENGINE COMPRESSION
Compression pressure
................................................................................................................................................. 1,283
kPa (13.0 kgf/cm2, 185 psi) Minimum pressure
......................................................................................................................................................
1,135 kPa (1 1.5 kgf/cm2, 164 psi) Difference between each cylinder
............................................................................................................................ 100 kPa (1.0
kgf/cm2, 15 psi) or less
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3113
Compression Check: Testing and Inspection
COMPRESSION
NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking
the engine, measure the compression pressure.
NOTE: Always use a fully charged battery to obtain engine speed of 200 rpm or more.
Compression pressure 1,283 kPa (13.0 kgf/cm2, 185 psi) Minimum pressure: 1,135 kPa (1 1.5
kgf/cm2, 164 psi) Difference between each cylinder 100 kPa (1.0 kgf/cm2, 15 psi) or less
e. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into
the cylinder through the spark plug hole and
repeat steps (a) through (c) for cylinders with low compression. ^
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
^ If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
Intake ...................................................................................................................................................
.................. 0.10 - 0.30 mm (0.0039 - 0.0118 inch) Exhaust ...............................................................
................................................................................................... 0.20 - 0.40 mm (0.0079 - 0.0157
inch)
Specification
Intake ...................................................................................................................................................
................. 0.17 - 0.23 mm (0.0067 - 0.0090 inch) Exhaust ................................................................
.................................................................................................. 0.27 - 0.33 mm (0.0106 - 0.0129
inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 3117
Valve Clearance: Adjustments
NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature: 20°C) and cylinder head is installed on the cylinder block.
1. Remove the engine cover. 2. Remove air cleaner assembly. 3. Remove the surge tank.
a. Disconnect the ignition coil connector and remove the ignition coil. b. Disconnect the breather
hose (A) from the cylinder head cover.
c. Loosen the cylinder head cover bolts and then remove the cover (A) and gasket.
a. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain
cover.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 3118
HH Ex HAUET
a. Check only the valve indicated as shown. [No. 1 cylinder: TDC/Compression] measure the valve
clearance.
- Using a thickness gauge, measure the clearance between the tappet and the base circle of
camshaft.
- Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting tappet.
Valve clearance Specification Engine coolant temperature: 20°C [68°F] Limit Intake: 0.10 - 0.30
mm (0.0039 - 0.0118 inch) Exhaust: 0.20 - 0.40 mm (0.0079 - 0.0157 inch)
b. Turn the crankshaft pulley one revolution (360") and align the groove with timing mark T of the
lower timing chain cover.
a. Set the No. 1 cylinder to the TDC/compression. b. Remove the timing chain. c. Remove the
camshaft bearing caps (A).
g. Calculate the thickness of a new tappet so that the valve clearance comes within the specified
value.
h. Select a new tappet with a thickness as close as possible to the calculated value.
NOTE: Shims are available in 41 size increments of 0.015 mm (0.0006 inch) from 3.00 mm (0.118
inch) to 3.600 mm (0.1417 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 3120
i. Place a new tappet on the cylinder head.
NOTE: Apply engine oil at the selected tappet on the periphery and top surface.
m. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft
sprocket and camshaft sprocket timing marks. n. Recheck the valve clearance.
Valve clearance (Engine coolant temperature: 20°C [68°F]) [Specification] Intake: 0.17 - 0.23 mm
(0.0067 - 0.0090 inch) Exhaust: 0.27 - 0.33 mm (0.0106 - 0.0129 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications
COMPONENT
1515—13.”
m— 1.0.5.7: -125}
in - 11.1! [1.11 - 1.1.1.2: - m
COMPONENT
COMPONENT
1515—13.”
m— 1.0.5.7: -125}
in - 11.1! [1.11 - 1.1.1.2: - m
WATER PUMP
COMPONENT
REMOVAL
1. Drain the engine coolant.
WARNING: System is under high pressure when the engine is hot. To avoid danger of releasing
scalding engine coolant, remove the cap only when the engine is cool.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 3125
2. Remove drive belt (A).
INSPECTION
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if
necessary 2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the
coolant pump assembly if necessary 3. Check for coolant leakage. If coolant leaks from hole, the
seal is defective. Replace the coolant pump assembly
INSTALLATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 3126
Tighlming tnrqm
1.54 4* 1 m (0.! '- 1.flhfl.m. 5.?! - 1mm}
1. Install the water pump (A) and a new gasket (B) with 12 bolts.
Tightening torque 21.56 - 23.52 Nm (2.2 - 2.4 kgf.m, 15.91 - 17.36 ft. lbs.) 9.80 - 11.76 Nm (1.0 -
1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 7.84 - 9.8O Nm (0.8 - 1.O kgf.m, 5.78 - 7.23 ft. lbs.)
3. Install drive belt (A). 4. Fill with engine coolant. 5. Start engine and check for leaks. 6. Recheck
engine coolant level.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
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Radiator Cooling Fan Control Module: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3138
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3141
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3142
l
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35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3143
fi
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3 I I I - l i d “ fi l l fl l h l l - I ' I P - I fl u — l
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3144
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3146
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3147
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3148
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3149
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3150
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3151
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3152
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions
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Radiator Cooling Fan Motor: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3157
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3160
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3161
l
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Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3162
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3163
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3165
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3166
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3167
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3168
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3169
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3170
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3171
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Locations
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Radiator Cooling Fan Motor Relay: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3177
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
mmmmdfirfim uppa:
hfllulnwlnigfl
m _ m
w?r@:mmmmmrfll2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3180
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3181
l
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Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3182
fi
1...:
3 I I I - l i d “ fi l l fl l h l l - I ' I P - I fl u — l
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3183
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3185
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3186
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3187
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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SPECIFIEATI‘DH
Component Location
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DESCRIPTION
1. Water temperature sensor(A) is located at the heater unit. 2. It detects coolant temperature. Its
signal is used for cold engine lockout control. When the driver operates the heater before the
engine is warmed
up, the signal from sensor causes the heater control unit to reduce blower motor speed until
coolant temperature reaches the threshold value.
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INSPECTION
1. Ignition "OFF". 2. Disconnect water temperature sensor connector. 3. Using the multi-tester,
Measure resistance between terminal "1" and "2" of water temperature sensor. 4. If the measured
resistance is not specification, substitute with a known-good water temperature sensor and check
for proper operation.
REPLACEMENT
2. Pull out the passenger's crash pad center low cover (A). 3. Remove the under cover after
loosening 2 screws. 4. Disconnect the connector (A) of water temperature sensor.
5. Pull the water temperature sensor(B) out at the heater unit with the stopper (C). 6. Install in the
reverse order of removal.
NOTE: Take care that wire of water temperature sensor is not to be damaged.
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Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
3203
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Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
3204
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Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
3205
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
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3206
DESCRIPTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
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3207
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Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
Specification
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3208
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Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
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Symbols Part 1
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Instructions > Page 3218
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Diagram Information and
Instructions > Page 3227
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Diagrams > Page 3228
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1. Using an ohmmeter, measure the resistance between the terminal 2 and ground.
2. If the resistance value is not as shown in the table, replace the temperature sender.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair
CDHPDI’EHTE
a. Humaraapnrmr [Brahma]
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Components (Part 2)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions
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Temperature Gauge: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3238
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3241
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3242
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Symbols Part 1
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3243
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3244
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3247
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3248
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3249
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3250
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3251
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 3252
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Diagrams > Page 3253
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1. Disconnect the wiring connector (A) from the engine coolant temperature sender in the engine
compartment. 2. Turn the ignition switch ON. Check that the gauge needle indicates cool. Turn the
ignition switch OFF. 3. Connect a 12 V, 3.4 wattages test bulb between the harness side connector
and ground. 4. Turn the ignition switch ON.
5. Verify that the test bulb flashes and that the indicator moves to HOT.
If operation is not as specified, replace the engine coolant temperature gauge. Then recheck the
system.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Service and Repair
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Radiator: Service and Repair
RADIATOR
REMOVAL
2. Disconnect radiator upper and lower hoses (A). 3. Disconnect transaxle oil cooler hoses. 4.
Remove radiator bracket. 5. Remove radiator assembly.
INSTALLATION
1. Install radiator assembly. 2. Install radiator upper bracket. 3. Connect transaxle oil cooler hoses.
4. Connect radiator upper and lower hoses (A). 5. Fill with engine coolant. 6. Start engine and
check for leaks. 7. Recheck engine coolant level.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions
.
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Radiator Cooling Fan Control Module: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
3262
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
wfif?)@:mmmmmmrul2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
3265
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
3266
35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
3267
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
3268
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
3270
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3272
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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3273
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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3274
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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3275
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3276
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Radiator Cooling Fan Motor Relay > Component Information > Locations
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Radiator Cooling Fan Motor Relay: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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3282
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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3285
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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3286
35
3
Symbols Part 1
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3287
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3288
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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3290
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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3291
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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3293
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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3294
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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3295
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3296
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor / Switch HVAC > Component Information >
Specifications
SPECIFIEATI‘DH
Component Location
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Specifications > Page 3303
DESCRIPTION
1. Water temperature sensor(A) is located at the heater unit. 2. It detects coolant temperature. Its
signal is used for cold engine lockout control. When the driver operates the heater before the
engine is warmed
up, the signal from sensor causes the heater control unit to reduce blower motor speed until
coolant temperature reaches the threshold value.
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Specifications > Page 3304
INSPECTION
1. Ignition "OFF". 2. Disconnect water temperature sensor connector. 3. Using the multi-tester,
Measure resistance between terminal "1" and "2" of water temperature sensor. 4. If the measured
resistance is not specification, substitute with a known-good water temperature sensor and check
for proper operation.
REPLACEMENT
2. Pull out the passenger's crash pad center low cover (A). 3. Remove the under cover after
loosening 2 screws. 4. Disconnect the connector (A) of water temperature sensor.
5. Pull the water temperature sensor(B) out at the heater unit with the stopper (C). 6. Install in the
reverse order of removal.
NOTE: Take care that wire of water temperature sensor is not to be damaged.
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Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
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Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3309
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Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3310
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3311
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3312
DESCRIPTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
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Information > Specifications > Page 3313
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DESCRIPTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
Specification
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Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3314
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Schematic Diagram
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Diagram Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Diagram Information and Instructions > Page 3319
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Diagram Information and Instructions > Page 3323
35
3
Symbols Part 1
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Diagram Information and Instructions > Page 3324
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
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Diagram Information and Instructions > Page 3325
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Diagram Information and Instructions > Page 3332
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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3334
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1. Using an ohmmeter, measure the resistance between the terminal 2 and ground.
2. If the resistance value is not as shown in the table, replace the temperature sender.
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Diagrams > Diagram Information and Instructions
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Temperature Gauge: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Information > Diagrams > Diagram Information and Instructions > Page 3343
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Diagrams > Diagram Information and Instructions > Page 3348
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Diagrams > Diagram Information and Instructions > Page 3349
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Diagrams > Diagram Information and Instructions > Page 3350
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Diagrams > Diagram Information and Instructions > Page 3351
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Diagrams > Diagram Information and Instructions > Page 3352
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Diagrams > Page 3354
fi-‘Ema ‘—'"'--._
"i'__ 4 ' F _
{if
1. Disconnect the wiring connector (A) from the engine coolant temperature sender in the engine
compartment. 2. Turn the ignition switch ON. Check that the gauge needle indicates cool. Turn the
ignition switch OFF. 3. Connect a 12 V, 3.4 wattages test bulb between the harness side connector
and ground. 4. Turn the ignition switch ON.
5. Verify that the test bulb flashes and that the indicator moves to HOT.
If operation is not as specified, replace the engine coolant temperature gauge. Then recheck the
system.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
Thermostat
THERMOSTAT
INSPECTION
1. Immerse the thermostat in water and gradually heat the water. 2. Check the valve opening
temperature.
Valve opening temperature: 82°C (177°F) Full opening temperature: 95°C (205°F) If the valve
opening temperature is not as specified, replace the thermostat.
Valve lift: Minimum 10 mm (0.4 inch) at 95°C (205°F) If the valve lift is not as specified, replace the
thermostat.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 3359
COMPONENT
1515—13.”
m— 1.0.5.7: -125}
in - 11.1! [1.11 - 1.1.1.2: - m
THERMOSTAT
COMPONENT
REMOVAL
NOTE: Removal of the thermostat would have an adverse effect, causing a lowering of cooling
efficiency. Do not remove the thermostat, even if the engine tends to overheat.
INSTALLATION
Tightening torque 16.66 - 19.6 0 Nm (1.7 - 2.0 kgf.m, 12.30 - 14.47 ft. lbs.)
3. Fill with engine coolant. 4. Start engine and check for leaks.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
COMPONENT
1515—13.”
m— 1.0.5.7: -125}
in - 11.1! [1.11 - 1.1.1.2: - m
COMPONENT
COMPONENT
1515—13.”
m— 1.0.5.7: -125}
in - 11.1! [1.11 - 1.1.1.2: - m
WATER PUMP
COMPONENT
REMOVAL
1. Drain the engine coolant.
WARNING: System is under high pressure when the engine is hot. To avoid danger of releasing
scalding engine coolant, remove the cap only when the engine is cool.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Specifications > Page 3365
2. Remove drive belt (A).
INSPECTION
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if
necessary 2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the
coolant pump assembly if necessary 3. Check for coolant leakage. If coolant leaks from hole, the
seal is defective. Replace the coolant pump assembly
INSTALLATION
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Specifications > Page 3366
Tighlming tnrqm
1.54 4* 1 m (0.! '- 1.flhfl.m. 5.?! - 1mm}
1. Install the water pump (A) and a new gasket (B) with 12 bolts.
Tightening torque 21.56 - 23.52 Nm (2.2 - 2.4 kgf.m, 15.91 - 17.36 ft. lbs.) 9.80 - 11.76 Nm (1.0 -
1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
Tightening torque 7.84 - 9.8O Nm (0.8 - 1.O kgf.m, 5.78 - 7.23 ft. lbs.)
3. Install drive belt (A). 4. Fill with engine coolant. 5. Start engine and check for leaks. 6. Recheck
engine coolant level.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Locations
— — — - — — _ - — — —
4 Catalytic 1 3 t {Bank 1]
Catalytic Converter: Locations
Bank 1
Bank 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Specifications
Exhaust Manifold: Specifications
EE-IIIJ
{HI - 4.5, m:- 32.53}
EXHAUST MANIFOLD
COMPONENT
REMOVAL
1. Remove under cover (A). 2. Disconnect LH, RH rear oxygen sensor connector from bracket.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component
Information > Specifications > Page 3375
3. Remove front muffler (A). 4. Remove oil level gauge (A).
8. Disconnect RH front oxygen sensor connector from bracket. 9. Remove RH heat protector.
INSTALLATION
Tightening torque 39.2 - 44.1 Nm (4.0 - 4.5 kgf.m, 28.92 - 32.53 ft. lbs.)
Tightening torque 16.66 - 21.56 Nm (1.7 - 2.2 kgf.m,12.30 - 15.91 ft. lbs.)
Tightening torque 39.2 - 58.8N.m(4.0 - 6.0 kgf.m, 28.92 - 43.37 ft. lbs.)
t ans—mmu-n.o.nmauan
1. m m r
2. Guitar mung-
3. Mah muflhr
Muffler: Diagrams
EXHAUST SYSTEM
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications
EPEGAIFIBATIOHE Ema:
Launflmfifimhfllflw-EDM a. Hamlwr
Less than 4m {12.3w - 5cm
' DC 123‘: EDDI'IIIL [Indudanfl had}
DB 12?. 220W (Induclllnflfl laud}
DC 12%: EDDI‘IIA [lrduclanna Ind}
DB 12V, 1'!” {LED load]
DC 12V. EflDmA [Indudanna Infl}
Du 12v. 2mm (Indufiflnua luau}
DE: 12V, 2mm {Indmtanna had}
i Seal halt wamlng Indicator [Drharfflaaiat] DC 12?. 12W [LEI]l load}
Ea}- rlnla lllLlnlnaflnn an}: DE 1hr. 2W {Lanp luau}
DIE 12V. 21W {Lamp Infill
DE 1251': 2mm {mm-Elana: land]
DE 12H: Elfin“. {lndudlnna laud)
DC 12V. EflDn'IA {lndtlflanca luau]
DC 12V. 2mm {Induflarm laud]
. DC 12V. flan-IA {lndudarna land]
Brim dunr unlock rainy Dc 1‘25". 2mm. {Inductance luau]
Trunk. lid 1min actuator DC 12V. 2mm {Inductanm luau}
Specifications
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications > Page 3386
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions
THEE: -
. I . . . I . l H l . . . l H
I .. .l . . I . I l I . . l .
$;:-.
. - I - ...|._......L._... .
..I—I....i-rpr. .
p ..
H...H.H1..H....
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Information and Instructions > Page 3389
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
wfif?)@:mmmmmmrul2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Information and Instructions > Page 3392
E .
i tarmflghwbmmfiflmmr}
Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3393
35
3
Symbols Part 1
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Information and Instructions > Page 3394
.—
H
l
l
.r
.-
n
r
I
h
l
n
.—
I
n.
H
J
i.
l
I
I
Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3395
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Information and Instructions > Page 3399
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Information and Instructions > Page 3401
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Information and Instructions > Page 3402
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Information and Instructions > Page 3403
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3404
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BCM Module Input Signal Test (Part 2)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3407
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Connector Views: The Connector Pin Out Views for connectors shown on these diagrams can be
found on the Connector Pin Out images that follow
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3411
most sets of system diagrams.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 3412
DESCRIPTION
Body control module (A) receives various input switch signals controlling time and alarm functions
for the intermittent wiper timer, washer timer, rear defogger timer, seat belt reminder, delayed out
room lamp, central door lock, ignition key reminder, power window timer, door warning, tail lamp
auto cut, crash door unlock, auto door lock, 2-turn unlock, ignition key hole illumination control and
keyless entry & burglar alarm.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Initial Inspection and Diagnostic Overview
LH‘I'UHDAI VEHICLE DIAGNOSIS Tl
MDDEL : EDMTA D5
D1. ALBUMS TRANSAJILE
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TAIL LAMP 5W
AUTD LIGHT 5W
1. The body control module can diagnose by using the diagnosis tool more quickly.
The BCM communicates with the diagnosis tool and then reads the input/output value and drives
the actuator.
2. To diagnose the BCM function, select the menu of model and body control module.
3. To consult the present input/out value of BCM, "02. INPUT/OUTPUT MONITORING". It provides
information of BCM input/output conditions
of power supply, turn signal/brake lamp, headlamp, door, locks, outside mirror, wiper, auto-light
and transmitters etc.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Initial Inspection and Diagnostic Overview > Page 3415
L HYUNDAI 1I:.I|'EHII.".I:LE DIAGNOSIS
MODEL : SDIIIATA US
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4. To perform compulsory operation on BCM input factors, select "03. ACTUATION TEST"
USER OPTION MODE
The BCM ofters 3 items user option mode for a user convenience (Auto door lock, door key burglar
alarm, door lock state inform horn)
- It is able to set up the enable or disable of AUTO DOOR LOCK function or AUTO DOOR LOCK
operation vehicle speed when using it.
- It is able to set up the enable or disable of enter the burglar alarm mode when using door lock by
the key.
- It is able to set up the enable or disable of horn inform function when using door lock by the key or
RKE.
1. .
3. Select option "USER OPTION" and press ENTER. 4. Select option "AUTO DOOR LOCK
STATUS by using the direction button(up/down).
5. Select the parameter by using the direction button(left/right) and press ENTER to save it.
(Disable / Enable).
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Initial Inspection and Diagnostic Overview > Page 3417
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1. With the tail lamp switched ON, if the ignition is switched OFF and the driver's door opened, the
tail lamp should be automatically turned
OFF.
2. With the ignition switch ON, if the driver's door is opened and the ignition is switched to OFF, the
tail lamp should be automatically turned
OFF.
3. When the tail lamp is cut automatically and the tail lamp switch is turned OFF and ON, the tail
lamp illuminates and auto cut function is
cancelled.
4. When the tail lamp is cut automatically and the ignition key is inserted, the tail lamp illuminates
and auto cut function is canceled.
1. Ignition keyhole illumination is turned ON when the driver or passenger door is opened. 2. The
"ON" state for ignition keyhole illumination is delayed 10 seconds when the door is closed as in
Step 1). 3. Ignition keyhole illumination is turned off if the ignition switch is turned ON as in Step 1)
& 2).
4. Ignition keyhole illumination is turned off if ARM state is entered. See Steps 1) & 2).
1. When the first door (driver, or assist or 4doors) is opened, room amp is turned on. 2. When the
door is closed, the room lamp is faded out for 2 seconds after there is on for 30 seconds. 3.
Regardless of ignition ON/OFF in door open state, room lamp output is ON. 4. When remote
control unlock is received, room lamp is turned on for 30 seconds
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Initial Inspection and Diagnostic Overview > Page 3418
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5. While room lamp is on due to Remote control unlock, if another remote control unlock is
received, then room lamp is again on for 30 sec.
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6. CENTRAL DOOR LOCK function is not performed during or after CRASH UNLOCK signal
output.
But, CENTRAL DOOR LOCK function is performed normally if CRASH UNLOCK function is reset
after IG OFF
6. 2-TURN UNLOCK
1. All door unlock signals are output for T2 if driver door key unlock switch is turned ON within T1
after changing driver door key unlock switch
from OFF to ON (mechanically, driver door key unlock switch is unlocked and BCM signal is not
output). (All door unlock signals are output even within T1 after RKE UNLOCK signal is received.)
2. Driver door unlock signal is output for T2 when RKE UNLOCK signal is received. But, all door
unlock signals are output for T2 if RKE
UNLOCK signal is received within T1. (All door unlock signals are output for T2 even when RKE
UNLOCK signal in T1 is received after changing driver door key unlock switch from OFF to ON.
1. This does not activate when vehicle speed is less than 5km/h. 2. Lock signal is output if vehicle
speed is 5km/h or more for at least is under ALT" L" ON, IGN SW = ON. But, lock signal is not
output if all
3. Lock signal is output 3 times as Max ((2) is ignored) if either one door is unlocked after lock
signal output in (2).(1s cycle) But, door, which is
4. Relevant door is fail if the state is unlock after 3-time output. 5. Lock signal is output once if the
fail door is unlocked again after the door is locked.
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Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Initial Inspection and Diagnostic Overview > Page 3420
6. Lock signal is output once if locked doors, which are lock state after lock signal output in (2),are
unlocked again.
But, lock signal is output once for the relevant door even when unlock state continues after lock
signal output.
8. Auto door lock function is not performed when crash unlock condition is met
1. This function is not performed when vehicle speed is 3km/h or more. 2. DRIVER UNLOCK signal
is output for is after 0.5s from when the state becomes KEY IN SW = IN & DRIVER DOOR = OPEN
& DRIVER
3. ALL DOOR UNLOCK signals are output for is after 0.5s from when the state becomes KEY IN
SW = IN & ASSIST DOOR = OPEN &
4. UNLOCK signal is output 3times as Max (Is-output is excluded) in case LOCK state is held even
when UNLOCK signal is output for Is in
1. If the key is in the key cylinder and the driver door is opened, the buzzer is sounded (period: 0.7
sec., duty rate: 50%).
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Initial Inspection and Diagnostic Overview > Page 3421
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2. If the ignition key is removed, or the door is closed, the buzzer is switched OFF immediately.
10. WINDSHIELD DEICER & DEFOGGER TIMER
1. Once ALT "L" is ON, if the defogger is switched ON, the defogger will stay ON for 20 minutes
duration.
2. If defogger switch is pressed again (see Step 1), or if ignition is switched OFF the defogger will
shut OFF.
1. When the ignition is switched OFF, power window output remains ON for 30 seconds and then
turns OFF 2. Related to Step 1), if the driver's door or assist door is opened, window power output
is turned OFF immediately.
3. When the driver's door or assist door is opened, the power window relay output is turned OFF
immediately.
- If washer switch is turned on, wiper output is ON after 0.3 sec. (T5)
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Initial Inspection and Diagnostic Overview > Page 3422
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- If washer switch is turned OFF, wiper output is OFF after 3.8 sec. (T6)
2. If the washer switch is turned OFF within 0.6 sec. (T2), the wiper will remain ON for up to 0.7
sec. (T3) from the moment that washer switch
is turned OFF
1. With the ignition switch ON, if the intermittent wiper switch is turned on, wiper output is ON
according to the setting.
2. When the intermittent wiper switch is ON, if the ignition switch is turned ON, wiper output is ON.
1. Warning lamp lights every 0.6sec and buzzer sounds every 1sec for 6 sec when IGN is ON
under unfastened seat belt.
(Warning lamp continues to light for 6 sec if seat belt is fastened within 6 sec) 30 seconds time
count starts at ALT "L" ON under this state.(30 seconds time count starts after 6 sec. if ALT" L" is
ON within initial 6 sec)
2. Buzzer stops and the warning lamp is turned OFF when IGN is turned OFF within 6 seconds
output. 3. Buzzer stops and the warning lamp is turned OFF and 30 seconds time count also stops
when seat belt is fastened after IGN ON. 4. If unfastened seat belt state continues after 60 seconds
time count from ALT" ON, the warning lamp flashes and buzzer sounds 11 times in 30
sec-cycle (6 sec ON/ 24 sec OFF) after 30 sec from ALT "L" ON.
5. Warning lamp & buzzer are turned OFF when IGN is OFF or seat belt is fastened during (4). 6.
Operation in (1) is performed when seat belt is unfastened again under ALT "L" ON and fastened
seat belt. 7. Operation in (4) is performed when ALT "L" is turned ON again after turning OFF under
unfastened seat belt.
1. Warning lamp lights continuously every 0.6 sec when IGN is turned ON under unfastened seat
belt. 2. Warning lamp is turned OFF when IGN is turned OFF within 0.6sec. 3. When IGN is ON
under unfastened seat belt, the warning lamp lights. The lamp continues to light for remaining time
of 6 sec when seat belt is
fastened within 6 sec. The lamp is OFF if seat belt is fastened after 6 sec.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Initial Inspection and Diagnostic Overview > Page 3423
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4. After 6 sec from IGN ON, warning lamp continues to flash when S/BELT is unfastened and stop
immediately when S/BELT is fastened.
16. AUTO LIGHT CONTROL
1. Auto light sensor value is always read at IGN ON. 2. Light is turned ON after 2 sec ± 0.2sec
when auto light sensor value is same as light ON input value. 3. Light is turned OFF after2 sec ±
0.2sec when sensor value is same as light OFF input value. 4. Tail lamp and head lamp are turned
ON when sensor value is same as tail lamp ON input value. 5. Light ON value of sensor is based
on the below table. 6. Head lamp signal is output when head lamp switch is ON. 7. After head lamp
is turned OFF, head lamp signal output is kept if head lamp ON luminance condition is met at auto
light switch ON. 8. After head lamp is turned OFF, head lamp signal output is immediately stopped
if head lamp OFF luminance condition is met at auto light
switch ON.
9. After head lamp is turned OFF, head lamp signal output is immediately stopped at tail switch
signal input. 10. After head lamp is turned OFF, head lamp signal output is stopped after 0.7 sec. if
there is no input of auto light switch or tail switch. (Shall be
11. Head lamp signal output is stopped when switch position is changed from AUTO to head lamp
switch during head lamp ON with auto light.
12. The condition of head lamp ON/OFF is same as the one of tail lamp ON/OFF at auto light
switch ON. Light ON value of the input sensor is
REPLACEMENT
1. Disconnect the negative (-) battery terminal. 2. Remove the floor console.
3. Remove the keyless antenna cable and body control module (A) after loosening 2 nuts. 4.
Installation is the reverse of removal.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations
Detail
'-
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Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations >
Page 3428
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638
Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P2135/P0638
Group: FUEL SYSTEM
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3437
From:
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3438
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3442
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NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3444
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3445
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3446
Tm: I: pun-gran for updltlng EDI.
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4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3447
I«'Iehuirflle 51W Management
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6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3448
ECU Upgrade
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8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 3449
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
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Number 10-FL-002
Subject ECM UPDATE - MIL ON DTC P161B - HARD START/ROUGH IDLE COLD
DESCRIPTION:
This bulletin provides information related to the ECM Update (software) of the applicable listed
vehicles below some of which may experience a malfunction indicator lamp illuminated with the
following system-related DTC:
^ P161B: (ECM Torque Calculation Performance). Vehicle may exhibit hard start and rough idle at
cold start. This is a cold start issue related to
NOTE:
DTC P1295, P2105 and/or P2106 may also set together with P161B after vehicle was running in
limited power limp home mode.
This update will also resolve the following system related DTC issues that may occur to some
vehicles, but not result in drivability issues:
NOTE:
To verify the vehicle is affected, be sure to check the version of the vehicle's engine control unit
ROM ID with reference to the ROM ID Information Table shown below before attempting to update
the control unit software.
Refer to below tables for Santa Fe and Sonata as to applicable ROM-ID's for this TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-002 > Jan > 10 > Engine Controls - MIL ON/Multiple DTCs/Rough Idle > Page 3456
WHY Hint! FOIGH] 3.3L 1Ml'l'll'l H-ll'li - Upclltl “In! #155:
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-002 > Jan > 10 > Engine Controls - MIL ON/Multiple DTCs/Rough Idle > Page 3457
m-mmv SeneteINF} 3.3!. with K-Ilne - Update event #153:
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Service Procedure
CAUTION:
state for reliable update results. The ECM Update procedure contains a check to ensure that
battery voltage is above 12 volts to allow the procedure to occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 20% or more charge
remaining. Charge the laptop battery with the AC
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, A/C, blower, radio, seat warmer, defroster, etc.)
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
2. Enter the vehicle information by pressing the VIN Auto Detect button, entering the vehicle's VIN
or selecting the vehicle model, model year, engine/fuel type and ENGINE as the system and then
click OK.
3. Select ECU Upgrade on the initial screen after entering the vehicle information.
4. Select Auto Mode then ENGINE in the left ECU Upgrade column.
7. After the Current ROM ID is displayed, select the Upgrade Event that appears in the pulldown
list it will be either of these as listed below:
NOTE:
Choose a later Event # if it appears in the Auto Mode pull-down list as it will contain fixes for other
more recent issues as well as for the issues identified by this TSB.
8. After clicking the Upgrade button, read Information then click OK.
9. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine for 10 minutes or longer to ensure
an adequate battery charge state for reliable update results.
10. Update will begin and the progress of the update will appear on the bar graph.
11. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
m 335331“ W
g ECUUpgrada
ltuntnlllflllfll I 'Lfllflflflfllfll
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13. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
CAUTION:
^ Manual update should be performed only when automatic update fails after the ECM update had
begun showing the progress bar.
^ Pull out the ECM fuse from the engine compartment junction box or disconnect the battery
negative cable for at least one minute to reset the control
unit before performing manual upgrade. Turn the ignition key back to the ON position.
^ If neither of the above works disconnect the connectors from the ECM for 10 minutes and try
again.
1. Within the ECU Upgrade screen, select Manual Mode in the left column, then select the
appropriate upgrade event# from the below table. Select the appropriate control unit part number
with reference to the ROM ID Information Table and click OK.
CAUTION:
Be sure to select NON IMMO part number for the correct vehicle as Santa Fe and Sonata vehicles
in USA do not have immobilizer.
2. Enter the appropriate password from the tables below and click OK.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-002 > Jan > 10 > Engine Controls - MIL ON/Multiple DTCs/Rough Idle > Page 3461
IIEHU PAEWDHD
GM 3 3 “DH IMMD 39113-3333":I
3. 3 ”DH IMMD: 39113—36551 3531
airman
MENU PAESWDHD
NF 3.3 DEW HUN ll'w'll'ul'IIIZTJl : 33113-3C33I3 33311
NF 3.3 MW HDNIMMD :39113—3C?E1 3TH
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
4. Update will begin and the progress of the update will appear on the bar graph.
5. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
7. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the upgrade and
clear the DTC (s) present.
CAUTION:
There are 2 ROM-ID of the 2008MY Sonata ROM-ID table that require VIN write after the reflash.
DTC P0630 may set for a No VIN error. Perform the VIN write and clear the DTC after.
Hut-ELM HDIIEL
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Engine Control Module: Customer Interest A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's
Set
Group TRANSAXLE
Number 09-AT-018
Subject ATA SOLENOID DIAGNOSTIC TROUBLE CODES P0740, P0741, P0742, P0743, P0746,
P0748, P0750, P0755, P0760, P0765, P0770
This TSB supersedes TSB# 05-40-006 to change the test procedure (Step 5) and add additional
models.
DESCRIPTION:
Incorrect operation of the transaxle solenoids may result in the following symptoms:
^ Diagnostic Trouble Codes P0740, P0741, P0742, P0743, P0746, P0748, P0750, P0755, P0760,
P0765 or P0770 set
NOTE:
Do NOT replace the transaxle for solenoid codes listed as open/short. Instead, follow the repair
procedure shown below.
APPLICABLE VEHICLES:
NOTE:
Refer to TSB 09-AT-011 for 2007~10 (HD) Elantra Sedan and (FD)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Bulletins > Customer Interest: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page
3466
PARTS INFORMATION
REPAIR PROCEDURE:
1. Using a GDS, check for DTC in both the "Engine" and "Automatic Transaxle" menus. Record the
DTC and description.
^ Vehicle
^ "Actuation Test"
^ Press the "Start" button and listen for a solenoid sound and "Success" indication.
^ Fail: go to Step 3
^ Success: the wiring between the PCM/TCM currently has no open or short circuits. Go to Step 4.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Bulletins > Customer Interest: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page
3467
J .I -'-JI l . l ' . l l l III'l-IIII-I luli I n Mr-
in!!!El" IHII'
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Data. Trualm-arrl
In SpEEHDI‘l I Test .-_._.,
MODEL Harman PM
4530131955:
Refer to parts catalog
45305—330“
NOTE:
This test confirms the wiring harness currently does not have an open or short circuit. It does not
confirm the proper functioning of the solenoids under all conditions of heat and vibration or a
solenoid with an intermittent open/short condition.
3. If Step 2 shows an inoperative solenoid, visually check the wiring harness between the TCM and
transaxle for a damaged wire or a short circuit to ground. Disconnect the connectors to the
solenoids at the transaxle and the PCM/TCM and check for a bent pin or a pin not fully inserted into
the connector. If so, repair or replace the ECM control harness, P/N 914xx-xxxxx.
4. Check the harness inside the transaxle oil pan for a short circuit to ground. Replace the harness
if damage is found or if three or more solenoid DTC are found in Step 1. (Refer to TSB#04-40-015
for replacement instructions).
5. Refer to the DTC recorded in Step 1 and follow the repair procedure shown below:
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Bulletins > Customer Interest: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page
3468
DTD REPAIR PRDEEDURE
I F0740. F0740. F0740. F0700. F0700. F0700.
F0705. F0770. F0740 at Ram-ea the related Inlanaidl
I F0743 {ll' F0740. F0741 0r F0742 Illfl let}
I P0740 [I70 duhh auntral syntarn pru-hllm} manlyr Clint “Ennina” and I*‘l'nlnla.'«:la" rnanu far 070:
I P0741 [WC duhh stuck all] ulnmlqI I ll' OTC P0330 nr P0720: Fallmu pmdura Hall.
I P0742 [1'10 dutch stuck an] ::Iln|3,I I lfng 0T0 P0330 ur P0720: Raplaua tha haul-:0-
[If nu afllar anlanuid 0T0 all)
P0330 (Crankshaft pualllnn annular rnalhncllnn} I check hill!!! and unnnaabara tn CHIP aanlnr
and ECWTGM. If DH. replace CHIP IIIIIDI'.
F0720 {GHF mam - 000“ almalt}
I fill!!! lullnnid DTG.
P1520 - TGlll MIL maul: algnal
Damned:
P0700 - TCM MIL mutual: algnal
0'0
LEE
RED
VFE
BITE REPAIR
10. Refer to the DTC recorded in Step 1 and replace the related solenoid according to the diagram
shown. Tighten the bolts to 4-5 lb.ft (50-70 kg.cm). Go to step 11.
11. Apply Permatex Ultra Gray Sealer or Hyundai Ultra Gray Gasket Sealer, P/N 00231-13800 to
the valve body cover and reinstall the cover. Tighten the bolts to 6-7 lb.ft (80-100 kg.cm).
12. Reinstall the radiator hoses and add ethylene glycol coolant to the radiator and overflow bottle.
Adjust the level according to the appropriate shop manual, "EM" section.
13. Add approximately five quarts of Hyundai SPIII ATF and check the level with the engine idling
in Neutral. Refer to TSB 06-40-016 and adjust the ATF level when the ATF is at normal operating
temperature (70-80°C, 158-176°F).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe Mode/Multiple Solenoid DTC's Set > Page
3469
2% {FIG} ham
EDIE-{IE [EP1E111001'530
3003-03 {3101103555 11531155555115.3530 433330.00 3.3 55313-33031
3001~05131133515005 11501555 55155530 4337311013 35 55313-33031
50505351550515 5255051013 533331030 0.3 3:55
14. Clear the codes and test drive the vehicle for two driving cycles (two key-on to key-off driving
cycles, including 1-2-3-4 upshifts and 4-3-2-1 downshifts). If the DTC returns, perform the repairs
shown above.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441 Set
Number 09-FL-008
DESCRIPTION:
Some 2006-2007 Sonata (NF) 3.3L / Azera (TG) 3.8L, and 2007 Santa Fe (CM) 3.3L vehicles may
experience malfunction indicator lamp illumination for DTC P0441 (Evaporative Emission System -
Incorrect Purge Flow).
NOTE:
APPLICABLE VEHICLES: ^ 2006-2007 Sonata (NF) 3.3L ^ 2006-2007 Azera (TG) 3.8L ^ 2007
Santa Fe (CM) 3.3L
NOTE:
To verify the vehicle is affected, be sure to check the version of the vehicle's engine control unit
ROM ID with reference to the ROM ID Information Table mentioned below before attempting to
update the control unit software.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441 Set > Page 3474
HUM ID
5cm H" auug new
CHENSTSEAfiHEEB I CME-NSTEIASESM
CHEN33*51A5'553AA Il' CHEHETEIAEEEIEEA
39110 _ CHENETSEAE'EEECAJ CHENETSZAS'EEM
313530 CHENE‘SEAEEEEEC .Ir CMEHETEEAEET'IM ( : m
CHEN33*52A55T1HA I CHEHETSEASBT‘IDA
CHEN33* 5355?1 F A } CHEN33*52A5571HA
CMEHH'fiEflEEflW
3511a _ CHBHETSEASEHCAI CMEHETSEASEHEA
ECEE'I CHEHEE'EEASET‘I GA! CHBHET SW'LJA CHEHWEIASW
CHEH3T52A55335A
EL'II PM "a" In
FEEVIDLIE HEW
TGSHBB‘MEAEED'IAA! 155"arunssmaa
Tasuaruznssnzu nssuaruznssm BE
39110-302111 Tafinawmznssacn HasnawmznssEznn
1'55"33*M2A55E3AA ,. Tssuaamzmsaam
TGEHH‘MEASESBBE I TGEHETHEASEEHBC Tfifllflfl IEAEEEEIA
3911Ila-3cm Taanwunsaauan : TGEHEE‘HIASEHAA
TGEHWMIAEEH BE I TGEHSE‘MEAEJEHEE
Tsfinaruznsanm
Ham ur- cun: ! or "A“! al- THE mum rnr Hlfl'UIIE Imus:
HF 3.3L 5:! 351111- _____
:Il 3.3L 31111!!a UPGRADE M Inn-I r Hula-m nun In taut In: NH cm
TE 3.3L {III-IJIIE] cur-mm Em Pill]:
Perform the ECM update when DTC P0441 occurs. If the condition exists after the ECM update,
perform EVAP system diagnostics related to DTC P0441 prior to replacing the Purge Control
Solenoid Valve (PCSV).
WARRANTY INFORMATION
Service Procedure
SERVICE PROCEDURE:
CAUTION:
^ Please ensure the following items during the control unit update.
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage for
days, run the engine to ensure an adequate battery charge
^ Turn off all lamps (Do not leave head lamp switch in auto mode) and all accessories (including
heater, A/C, blower, radio, seat warmer, defroster, etc.)
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
A: Diagnostic Terminal
B: VCI [Vehicle Cnmmunicatiun Intatfaca)
C: USB {Uniuaraal Serial Bus] Cable
D: i a r Supply Cable
E: DLC Gable
NOTE:
If attempting to perform the update with the power supply cable disconnected from the diagnostic
terminal, make certain that the diagnostic terminal is charged enough for the update. If not, the
update may fail in progress. Therefore, it is strongly recommended to connect the power supply
cable to the diagnostic terminal during the update procedure.
2. Connect the USB cable between the VCI and the diagnostic terminal.
NOTE:
When performing the update using the GDS, wireless communication between the VCI and the
diagnostic terminal is NOT available. Therefore, be sure to connect the USB cable between the
VCI and the diagnostic terminal.
3. Connect the 16-pin DLC cable from the VCI into the vehicle's 16-pin connector under the driver
side instrument panel.
4. Turn on the VCI and diagnostic terminal with the ignition key in the ON position.
NOTE:
Upgrada Hunt
135. NF 3.3 P2135 AND P0533 DTC LOGIC - [DEHUTM‘I’]
126. CM 2.?!3.3 132135 AND P0533 13TC LDGIC - K LINE
130. TB 3.3 F2135 AND F0533 DTC LEE-IE - Fri-LINE
2. Enter the vehicle information by pressing the VIN Auto Detect button, entering the vehicle's VIN
or selecting the vehicle model, model year, engine/fuel type and ENGINE as the system and then
click OK.
3. Select ECU Upgrade on the initial screen after entering the vehicle information.
4. Select Auto Mode then ENGINE in the left ECU Upgrade column.
8. After clicking the Upgrade button, read Information then click OK.
9. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
10. Update will begin and the progress of the update will appear on the bar graph.
11. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
13. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
CAUTION:
^ Pull out the ECM fuse from the engine compartment junction box or disconnect the battery
negative cable to reset the control unit before performing
manual update.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 09-FL-008 > Aug > 09 > Engine Controls - MIL ON/DTC P0441 Set > Page 3477
2. Within the ECU Upgrade screen, select Manual Mode in the left column, then select appropriate
upgrade event. Select the appropriate control unit part number with reference to the ROM ID
Information Table and click OK.
3. Enter the appropriate password from the table above and then click OK.
4. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
5. Update will begin and the progress of the update will appear on the bar graph.
6. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
Number: 08-AT-003
Model: 1999~ SONATA, 2001~06 ELANTRA, 2001~ SANTA FE & XG, 2003~ TIBURON, 2005~
TUCSON, 2006~ AZERA, 2007~ ENTOURAGE
This TSB supersedes TSB 07-40-010 to correct the labor time for OP Code 95440RP0 and
95440PQ0.
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed upshift or downshift,
follow the Diagnostic Procedure shown below.
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue with the diagnosis.
4. Attach the GDS and check for Diagnostic Trouble Codes in both the "Engine" and "Automatic
Transaxle" menu. If DTC's are found, repair according to the appropriate TSB or shop manual.
NOTE:
"Current Data"
^ "Shift position"
^ "Vehicle speed"
^ Select "PC Record" (on left of screen) and save the file.
"Items List" (top right of screen) and select: "Vehicle speed" and "Shift position".
PCM/TCM DIAGNOSIS:
Confirm the PCM or TCM commanded each gear: 1, 2, 3, 4 and 5 (if equipped): ^
If so, go to pages 3~6 and evaluate the upshift diagnosis for the related shift.
If not, exchange a PCM or TCM from a properly operating vehicle and test again to determine if the
PCM or TCM commanded each gear:
^ If the condition is not improved, go to page 3~6 and evaluate the upshift performance.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Underdrive Solenoid Duty"
and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 1-2 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The 2nd solenoid elapsed time is important; the shape of the graph is not.
['r':IL"Ir_II1II
I.'.l‘.l 'l'IH':I'I I
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "Underdrive Solenoid Duty", "Overdrive
Solenoid Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the OD solenoid elapsed time at the top right of the screen. If the 2-3 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive values":
NOTE:
The OD solenoid elapsed time is important; the shape of the graph is not.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Overdrive Solenoid
Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 3-4 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
. I
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Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "Reduction Solenoid Duty", Low-Reverse
Solenoid Duty and "Shift Position".
^
Select the "+" or "-" button to choose 0.7 sec./Div or less.
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the LR solenoid elapsed time at the top right of the screen. If the 4-5 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION:
NOTE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 08-AT-003 > May > 08 > A/T - Harsh/Delayed Upshift/Downshift > Page 3485
Warranty Claim requires input of DTC codes on all claims using Hi-Scan or GDS operations. If no
DTC code is identified by the Hi-scan or GDS, enter P0000 as a Scan Tool Test Code on the
Warranty Claim and attach printout from the Hi-scan or GDS to the Repair Order.
NOTE:
Printouts must be attached to all Repair Orders. Repair Orders without attached printouts are
subject to chargeback.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement
mm
ATF at nen'nel eperetfng temperature {158-212°F, FBI-1ETC}
‘ —
Engine Control Module: Customer Interest A/T - Harsh/Delayed Reverse or Drive Engagement
Group: TRANSAXLE
Number: 07-40-009-1
Models: 1999 - SONATA 2001-06 - ELANTRA 2001 - SANTA FE & XG 2003 - TIBURON 2005 -
TUCSON 2006 - AZERA 2007 - ENTOURAGE
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed shift into Drive or
Reverse, follow the Diagnostic Procedure shown below:
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
2. Perform the adaptive learning by shifting from Neutral to Reverse and Drive, stopping in each
gear for 5 seconds. Repeat 10 times.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue the diagnosis.
4. Check that idle speed is within specification. If not, inspect according to the appropriate shop
manual, "Fuel System Section".
5. Check the engine and transaxle mounting brackets and roll support brackets. If necessary,
replace the mounts.
6. Attach the GDS and check for Diagnostic Trouble Codes in both the "ENGINE" and
"AUTOMATIC TRANSAXLE" menus. If DTC are found, repair according to the appropriate TSB or
shop manual.
7. Attach the GDS and select "AUTOMATIC TRANSAXLE" menu, "CURRENT DATA" menu and
"FLUID TEMPERATURE SENSOR". Confirm the oil temperature sensor operates correctly as
shown. If not, inspect the oil temperature sensor according to TSB 04-40-016 or appropriate shop
manual.
8. Select "CURRENT DATA" and "TPS". Open and close the throttle and confirm the TPS
increases and decreases smoothly between approximately 0 - 100% duty.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 3490
' ; . . . _ I __ I .__..::.fi.-—I—r'_ ‘ i - F .‘ _
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9. Attach the GDS and select VIN and "A/T" "Current Data" and then select "Shift Position", "LR
Solenoid Duty" and "Underdrive Solenoid Duty" as shown.
10. Start the engine and move the shift lever between Neutral, Drive and Reverse, stopping 3-5
seconds in each gear.
11. Select "Record shown" at the top right of the screen. GDS will record up to 10 minutes data
prior to selecting "Record".
12. Select "PC Record" (top left of screen), then save file.
13. Select "Flight Record" and "Data Review", select the vehicle and open the file.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 3491
. _'=' 1':I::!|-'iF¢I-"
_ I : ,l_-_.'LI| H" 111114" n; :- uni-Hm Inh- IE
Data, 1mm:
Flight Rfinnrd IIJIJ'I-
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14. Select "Items List" (top right of screen), then select "Shift Position", "LR Solenoid Duty" and
"Underdrive Solenoid Duty".
16. Move the cursor to the start of the shift and "Left click".
17. Move the cursor to the end of the shift and "Right Click".
18. Read the Low & Reverse solenoid engagement time on the top right of the screen. If the P-R
shift requires more than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle
and follow TSB 06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
20. Select "Items List" (top right of screen), then select "Shift Position LR Solenoid Duty" and
"Underdrive Solenoid Duty".
22. Move the cursor to the start of the shift and "Left click".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed Reverse or Drive Engagement > Page 3492
1 . -. - - ‘Ru...|.|.l".l.-l-I.- I._J.-'l' —-_FI'TF'-
B nlc Incipient-III
cTc Anny-II: —
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Flight Retard PM
IJWTJRIIT’? '-
ufiflfcfif"m5‘-Z'
Iii-DRE EIED-H
EIIHIILIH Amara
NDTE: Warranty Claim requlrea Input cf DTG ccclea an all claims ualng Hl-Scan
cr GEE cperatiene. H' nc DTL": cede ie identified by the Hi-ecan er GDS,
enter Fflflflfl aa a Scan cl Teat Code on the Warranty Claim and attach
plintcut frcrn the Hi-acan er GDS tn the Repair Grder.
NDTE: Frintcuta must be attached to all Repair Drdars. Repalr Orders wlthcut
attached printcuts are subject tc chargeback.
23. Move the cursor to the end of the shift and "Right Click".
24. Read the UD engagement time on the top right of the screen. If the P-D shift requires more
than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The UD solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 11-AT-008 > Apr > 11 > A/T - TCM/ECM Adaptive
Value Rest/Relearn Procedure
: ; »
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Engine Control Module: All Technical Service Bulletins A/T - TCM/ECM Adaptive Value
Rest/Relearn Procedure
Group:AUTOMATIC TRANSAXLE
Number: 11-AT-008
Model: ALL
This bulletin supersedes TSB 10-AT-Oil to include 2011~ Elantra, 2012~ Accent and Genesis
Sedan.
After replacing a transaxle or reprogramming the PCM/TCM, follow this procedure to reset and
relearn the adaptive learning to improve shift quality.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
arm: jam- m
1.1mm
m-mm
'lv- II- Elm-1mm I f ! ! ! “
'Ia-I-Ifl-I nil ' 1 -1--.-q l-iflflf'flfl
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n 'wlmrr
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NDTE: * Clear CAN Lent-le Stltul anly n- Meeheireniee [vulva body] in Eldllnged frumMe:venlele
[Gene-II ASL. Equal MEL, and Gene-II Camp-e 3.0L wlfl'u 2F Inn-mlnlun].
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
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6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified TPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 11-AT-008 > Apr > 11 > A/T - TCM/ECM Adaptive
Value Rest/Relearn Procedure > Page 3501
Adaptive learning occurs only within the ATF temperature ranges shown.
WARRANTY INFORMATION:
“Mum m m F m
System
Sula-ct Sygtnm SEI acted System
“mamaHQ —
§@@@@@g
_ 7 —..:a__l—l-
Engine Control Module: All Technical Service Bulletins A/T Controls - Resetting PCM/TCM
Adaptive Values
Number: 10-AT-Oil
Model: ALL
Subject
This bulletin supersedes TSB 09-AT-002-1 to include Equus and Sonata HEV
CAUTION:
After replacing a transaxle or reprogramming the PCM/TCM, to improve the shift quality condition,
follow this procedure to reset and relearn the adaptive learning.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
HDTE: * Clear BAH Laarnahla sum: only If Mmhatrunlu {valva may: I: filfihfll’lflifl mam Inufllfl mun
[El-fillil 1.6L. Equus LEI. and GHI-flil- Gnupl 3.5L with 2F trim-ninth}.
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
m m m w w m fl n
' 1 ? t 'l-5 I."
6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified IPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-AT-011 > Aug > 10 > A/T Controls - Resetting
PCM/TCM Adaptive Values > Page 3509
NOTE:
Adaptive learning occurs only within the ATF temperature ranges shown:
WARRANTY INFORMATION:
Normal warranty applies
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638
Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's
P2135/P0638
Group: FUEL SYSTEM
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 3514
Frant
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 3515
mm ID
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NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 3521
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 3522
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 3523
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ROM ID Reading...
4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 3524
I«'Iehuirflle 51W Management
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6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 3525
ECU Upgrade
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update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-010 > Aug > 10 > Engine Controls - MIL
ON/DTC's P2135/P0638 > Page 3526
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
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Number 10-FL-002
Subject ECM UPDATE - MIL ON DTC P161B - HARD START/ROUGH IDLE COLD
DESCRIPTION:
This bulletin provides information related to the ECM Update (software) of the applicable listed
vehicles below some of which may experience a malfunction indicator lamp illuminated with the
following system-related DTC:
^ P161B: (ECM Torque Calculation Performance). Vehicle may exhibit hard start and rough idle at
cold start. This is a cold start issue related to
NOTE:
DTC P1295, P2105 and/or P2106 may also set together with P161B after vehicle was running in
limited power limp home mode.
This update will also resolve the following system related DTC issues that may occur to some
vehicles, but not result in drivability issues:
NOTE:
To verify the vehicle is affected, be sure to check the version of the vehicle's engine control unit
ROM ID with reference to the ROM ID Information Table shown below before attempting to update
the control unit software.
Refer to below tables for Santa Fe and Sonata as to applicable ROM-ID's for this TSB.
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-002 > Jan > 10 > Engine Controls - MIL
ON/Multiple DTCs/Rough Idle > Page 3533
WHY Hint! FOIGH] 3.3L 1Ml'l'll'l H-ll'li - Upclltl “In! #155:
Modal
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Previous
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m lmw-acm EHIHEE‘EEASBJHBF
CHMETEEASBJHCF M l fl m
CHHETSEASBJHEP
CHIHJTSEABHJIAF
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-002 > Jan > 10 > Engine Controls - MIL
ON/Multiple DTCs/Rough Idle > Page 3534
m-mmv SeneteINF} 3.3!. with K-Ilne - Update event #153:
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Service Procedure
CAUTION:
state for reliable update results. The ECM Update procedure contains a check to ensure that
battery voltage is above 12 volts to allow the procedure to occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 20% or more charge
remaining. Charge the laptop battery with the AC
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, A/C, blower, radio, seat warmer, defroster, etc.)
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
2. Enter the vehicle information by pressing the VIN Auto Detect button, entering the vehicle's VIN
or selecting the vehicle model, model year, engine/fuel type and ENGINE as the system and then
click OK.
3. Select ECU Upgrade on the initial screen after entering the vehicle information.
4. Select Auto Mode then ENGINE in the left ECU Upgrade column.
7. After the Current ROM ID is displayed, select the Upgrade Event that appears in the pulldown
list it will be either of these as listed below:
NOTE:
Choose a later Event # if it appears in the Auto Mode pull-down list as it will contain fixes for other
more recent issues as well as for the issues identified by this TSB.
8. After clicking the Upgrade button, read Information then click OK.
9. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine for 10 minutes or longer to ensure
an adequate battery charge state for reliable update results.
10. Update will begin and the progress of the update will appear on the bar graph.
11. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
Q ECU Upgrada
lEunlmflflllfll I ill-IRWIN
+- "PEI-d. Eflm |151cm 33 amen: HEHTEH Lam: IIIIPHEWEHEHT - cm
|= Ealflct system=
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CH 3.3 fl'ElH‘I' HUN IHHD I 39110-33555
CH 3.3 flQlIl‘I' IIIIHEI I 3911fl-3G51 5
lill'll'l I: .. |:..h II-L . . : . . l ' ! l . -
13. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
CAUTION:
^ Manual update should be performed only when automatic update fails after the ECM update had
begun showing the progress bar.
^ Pull out the ECM fuse from the engine compartment junction box or disconnect the battery
negative cable for at least one minute to reset the control
unit before performing manual upgrade. Turn the ignition key back to the ON position.
^ If neither of the above works disconnect the connectors from the ECM for 10 minutes and try
again.
1. Within the ECU Upgrade screen, select Manual Mode in the left column, then select the
appropriate upgrade event# from the below table. Select the appropriate control unit part number
with reference to the ROM ID Information Table and click OK.
CAUTION:
Be sure to select NON IMMO part number for the correct vehicle as Santa Fe and Sonata vehicles
in USA do not have immobilizer.
2. Enter the appropriate password from the tables below and click OK.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 10-FL-002 > Jan > 10 > Engine Controls - MIL
ON/Multiple DTCs/Rough Idle > Page 3538
IIEHU PAEWDHD
GM 3 3 “DH IMMD 39113-3333":I
3. 3 ”DH IMMD: 39113—36551 3531
.-;II* 1 . 1 1 v .
airman
MENU PAESWDHD
NF 3.3 DEW HUN ll'w'll'ul'IIIZTJl : 33113-3C33I3 33311
NF 3.3 MW HDNIMMD :39113—3C?E1 3TH
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
4. Update will begin and the progress of the update will appear on the bar graph.
5. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
7. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the upgrade and
clear the DTC (s) present.
CAUTION:
There are 2 ROM-ID of the 2008MY Sonata ROM-ID table that require VIN write after the reflash.
DTC P0630 may set for a No VIN error. Perform the VIN write and clear the DTC after.
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Engine Control Module: All Technical Service Bulletins A/T - MIL ON/Failsafe Mode/Multiple
Solenoid DTC's Set
Group TRANSAXLE
Number 09-AT-018
Subject ATA SOLENOID DIAGNOSTIC TROUBLE CODES P0740, P0741, P0742, P0743, P0746,
P0748, P0750, P0755, P0760, P0765, P0770
This TSB supersedes TSB# 05-40-006 to change the test procedure (Step 5) and add additional
models.
DESCRIPTION:
Incorrect operation of the transaxle solenoids may result in the following symptoms:
^ Diagnostic Trouble Codes P0740, P0741, P0742, P0743, P0746, P0748, P0750, P0755, P0760,
P0765 or P0770 set
NOTE:
Do NOT replace the transaxle for solenoid codes listed as open/short. Instead, follow the repair
procedure shown below.
APPLICABLE VEHICLES:
NOTE:
Refer to TSB 09-AT-011 for 2007~10 (HD) Elantra Sedan and (FD)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe
Mode/Multiple Solenoid DTC's Set > Page 3543
PARTS INFORMATION
REPAIR PROCEDURE:
1. Using a GDS, check for DTC in both the "Engine" and "Automatic Transaxle" menus. Record the
DTC and description.
^ Vehicle
^ "Actuation Test"
^ Press the "Start" button and listen for a solenoid sound and "Success" indication.
^ Fail: go to Step 3
^ Success: the wiring between the PCM/TCM currently has no open or short circuits. Go to Step 4.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe
Mode/Multiple Solenoid DTC's Set > Page 3544
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Refer to parts catalog
45305—330“
NOTE:
This test confirms the wiring harness currently does not have an open or short circuit. It does not
confirm the proper functioning of the solenoids under all conditions of heat and vibration or a
solenoid with an intermittent open/short condition.
3. If Step 2 shows an inoperative solenoid, visually check the wiring harness between the TCM and
transaxle for a damaged wire or a short circuit to ground. Disconnect the connectors to the
solenoids at the transaxle and the PCM/TCM and check for a bent pin or a pin not fully inserted into
the connector. If so, repair or replace the ECM control harness, P/N 914xx-xxxxx.
4. Check the harness inside the transaxle oil pan for a short circuit to ground. Replace the harness
if damage is found or if three or more solenoid DTC are found in Step 1. (Refer to TSB#04-40-015
for replacement instructions).
5. Refer to the DTC recorded in Step 1 and follow the repair procedure shown below:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe
Mode/Multiple Solenoid DTC's Set > Page 3545
DTD REPAIR PRDEEDURE
I F0740. F0740. F0740. F0700. F0700. F0700.
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and ECWTGM. If DH. replace CHIP IIIIIDI'.
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10. Refer to the DTC recorded in Step 1 and replace the related solenoid according to the diagram
shown. Tighten the bolts to 4-5 lb.ft (50-70 kg.cm). Go to step 11.
11. Apply Permatex Ultra Gray Sealer or Hyundai Ultra Gray Gasket Sealer, P/N 00231-13800 to
the valve body cover and reinstall the cover. Tighten the bolts to 6-7 lb.ft (80-100 kg.cm).
12. Reinstall the radiator hoses and add ethylene glycol coolant to the radiator and overflow bottle.
Adjust the level according to the appropriate shop manual, "EM" section.
13. Add approximately five quarts of Hyundai SPIII ATF and check the level with the engine idling
in Neutral. Refer to TSB 06-40-016 and adjust the ATF level when the ATF is at normal operating
temperature (70-80°C, 158-176°F).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-AT-018 > Oct > 09 > A/T - MIL ON/Failsafe
Mode/Multiple Solenoid DTC's Set > Page 3546
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3001~05131133515005 11501555 55155530 4337311013 35 55313-33031
50505351550515 5255051013 533331030 0.3 3:55
14. Clear the codes and test drive the vehicle for two driving cycles (two key-on to key-off driving
cycles, including 1-2-3-4 upshifts and 4-3-2-1 downshifts). If the DTC returns, perform the repairs
shown above.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-FL-008 > Aug > 09 > Engine Controls - MIL
ON/DTC P0441 Set
Number 09-FL-008
DESCRIPTION:
Some 2006-2007 Sonata (NF) 3.3L / Azera (TG) 3.8L, and 2007 Santa Fe (CM) 3.3L vehicles may
experience malfunction indicator lamp illumination for DTC P0441 (Evaporative Emission System -
Incorrect Purge Flow).
NOTE:
APPLICABLE VEHICLES: ^ 2006-2007 Sonata (NF) 3.3L ^ 2006-2007 Azera (TG) 3.8L ^ 2007
Santa Fe (CM) 3.3L
NOTE:
To verify the vehicle is affected, be sure to check the version of the vehicle's engine control unit
ROM ID with reference to the ROM ID Information Table mentioned below before attempting to
update the control unit software.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-FL-008 > Aug > 09 > Engine Controls - MIL
ON/DTC P0441 Set > Page 3551
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Perform the ECM update when DTC P0441 occurs. If the condition exists after the ECM update,
perform EVAP system diagnostics related to DTC P0441 prior to replacing the Purge Control
Solenoid Valve (PCSV).
WARRANTY INFORMATION
Service Procedure
SERVICE PROCEDURE:
CAUTION:
^ Please ensure the following items during the control unit update.
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage for
days, run the engine to ensure an adequate battery charge
^ Turn off all lamps (Do not leave head lamp switch in auto mode) and all accessories (including
heater, A/C, blower, radio, seat warmer, defroster, etc.)
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
A: Diagnostic Terminal
B: VCI [Vehicle Cnmmunicatiun Intatfaca)
C: USB {Uniuaraal Serial Bus] Cable
D: i a r Supply Cable
E: DLC Gable
^ Do not turn off the ignition switch during update.
NOTE:
If attempting to perform the update with the power supply cable disconnected from the diagnostic
terminal, make certain that the diagnostic terminal is charged enough for the update. If not, the
update may fail in progress. Therefore, it is strongly recommended to connect the power supply
cable to the diagnostic terminal during the update procedure.
2. Connect the USB cable between the VCI and the diagnostic terminal.
NOTE:
When performing the update using the GDS, wireless communication between the VCI and the
diagnostic terminal is NOT available. Therefore, be sure to connect the USB cable between the
VCI and the diagnostic terminal.
3. Connect the 16-pin DLC cable from the VCI into the vehicle's 16-pin connector under the driver
side instrument panel.
4. Turn on the VCI and diagnostic terminal with the ignition key in the ON position.
NOTE:
Upgrade Hunt
135. NF 3.3 P2135 AND PDEBB DTC LOGIC - [DE~DTMY)
125. CM 2.?!3.3 132135 AND P0533 ETC LDGIC - HE LINE
130. TB 3.3 F2135 AND F0633 DTC LEE-IE - Fri-LINE
2. Enter the vehicle information by pressing the VIN Auto Detect button, entering the vehicle's VIN
or selecting the vehicle model, model year, engine/fuel type and ENGINE as the system and then
click OK.
3. Select ECU Upgrade on the initial screen after entering the vehicle information.
4. Select Auto Mode then ENGINE in the left ECU Upgrade column.
8. After clicking the Upgrade button, read Information then click OK.
9. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
10. Update will begin and the progress of the update will appear on the bar graph.
11. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
13. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
CAUTION:
^ Pull out the ECM fuse from the engine compartment junction box or disconnect the battery
negative cable to reset the control unit before performing
manual update.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-FL-008 > Aug > 09 > Engine Controls - MIL
ON/DTC P0441 Set > Page 3554
2. Within the ECU Upgrade screen, select Manual Mode in the left column, then select appropriate
upgrade event. Select the appropriate control unit part number with reference to the ROM ID
Information Table and click OK.
3. Enter the appropriate password from the table above and then click OK.
4. The vehicle battery voltage is checked to make sure it is at least 12 volts to ensure reliable
update results. Click OK if the results indicate Voltage is OK.
NOTE:
If voltage is below 12 volts, click Cancel and then run the engine to ensure an adequate battery
charge state for reliable update results.
5. Update will begin and the progress of the update will appear on the bar graph.
6. Updating will occur until 100% is reached on the bar graph. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then click OK to continue according to Information
displayed on the screen.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (s) present.
Number: 08-AT-003
Model: 1999~ SONATA, 2001~06 ELANTRA, 2001~ SANTA FE & XG, 2003~ TIBURON, 2005~
TUCSON, 2006~ AZERA, 2007~ ENTOURAGE
This TSB supersedes TSB 07-40-010 to correct the labor time for OP Code 95440RP0 and
95440PQ0.
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed upshift or downshift,
follow the Diagnostic Procedure shown below.
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue with the diagnosis.
4. Attach the GDS and check for Diagnostic Trouble Codes in both the "Engine" and "Automatic
Transaxle" menu. If DTC's are found, repair according to the appropriate TSB or shop manual.
NOTE:
"Current Data"
^ "Shift position"
^ "Vehicle speed"
^ Select "PC Record" (on left of screen) and save the file.
"Items List" (top right of screen) and select: "Vehicle speed" and "Shift position".
PCM/TCM DIAGNOSIS:
Confirm the PCM or TCM commanded each gear: 1, 2, 3, 4 and 5 (if equipped): ^
If so, go to pages 3~6 and evaluate the upshift diagnosis for the related shift.
If not, exchange a PCM or TCM from a properly operating vehicle and test again to determine if the
PCM or TCM commanded each gear:
^ If the condition is not improved, go to page 3~6 and evaluate the upshift performance.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Underdrive Solenoid Duty"
and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 1-2 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The 2nd solenoid elapsed time is important; the shape of the graph is not.
['r':IL"Ir_II1II
I.'.l‘.l 'l'IH':I'I I
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "Underdrive Solenoid Duty", "Overdrive
Solenoid Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the OD solenoid elapsed time at the top right of the screen. If the 2-3 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive values":
NOTE:
The OD solenoid elapsed time is important; the shape of the graph is not.
Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review"
^ Select "Items List" (top right of screen) and select: "2nd Solenoid Duty", "Overdrive Solenoid
Duty" and "Shift Position".
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the 2nd solenoid elapsed time at the top right of the screen. If the 3-4 shift requires more
than 2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
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Open the GDS program and select: VIN and "A/T", "Flight Record" and "Data Review" ^
Select "Items List" (top right of screen) and select: "Reduction Solenoid Duty", Low-Reverse
Solenoid Duty and "Shift Position".
^
Select the "+" or "-" button to choose 0.7 sec./Div or less.
Move the cursor to the start of the shift and "Left click".
Move the cursor to the end of the shift and "Right click".
Read the LR solenoid elapsed time at the top right of the screen. If the 4-5 shift requires more than
2.0 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION:
NOTE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-AT-003 > May > 08 > A/T - Harsh/Delayed
Upshift/Downshift > Page 3562
Warranty Claim requires input of DTC codes on all claims using Hi-Scan or GDS operations. If no
DTC code is identified by the Hi-scan or GDS, enter P0000 as a Scan Tool Test Code on the
Warranty Claim and attach printout from the Hi-scan or GDS to the Repair Order.
NOTE:
Printouts must be attached to all Repair Orders. Repair Orders without attached printouts are
subject to chargeback.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed
Reverse or Drive Engagement
mm
ATF at nen'nel eperetfng temperature {158-212°F, FBI-1ETC}
‘ —
Engine Control Module: All Technical Service Bulletins A/T - Harsh/Delayed Reverse or Drive
Engagement
Group: TRANSAXLE
Number: 07-40-009-1
Models: 1999 - SONATA 2001-06 - ELANTRA 2001 - SANTA FE & XG 2003 - TIBURON 2005 -
TUCSON 2006 - AZERA 2007 - ENTOURAGE
DESCRIPTION:
If you are diagnosing an automatic transaxle with a harsh and/or delayed shift into Drive or
Reverse, follow the Diagnostic Procedure shown below:
DIAGNOSTIC PROCEDURE:
1. Check the ATF level when the engine is idling in "N" according to TSB 06-40-016. Adjust the
ATF level as needed.
2. Perform the adaptive learning by shifting from Neutral to Reverse and Drive, stopping in each
gear for 5 seconds. Repeat 10 times.
3. Compare to a similar model and year vehicle. If the shift delay is longer than the comparison
vehicle, continue the diagnosis.
4. Check that idle speed is within specification. If not, inspect according to the appropriate shop
manual, "Fuel System Section".
5. Check the engine and transaxle mounting brackets and roll support brackets. If necessary,
replace the mounts.
6. Attach the GDS and check for Diagnostic Trouble Codes in both the "ENGINE" and
"AUTOMATIC TRANSAXLE" menus. If DTC are found, repair according to the appropriate TSB or
shop manual.
7. Attach the GDS and select "AUTOMATIC TRANSAXLE" menu, "CURRENT DATA" menu and
"FLUID TEMPERATURE SENSOR". Confirm the oil temperature sensor operates correctly as
shown. If not, inspect the oil temperature sensor according to TSB 04-40-016 or appropriate shop
manual.
8. Select "CURRENT DATA" and "TPS". Open and close the throttle and confirm the TPS
increases and decreases smoothly between approximately 0 - 100% duty.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed
Reverse or Drive Engagement > Page 3567
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9. Attach the GDS and select VIN and "A/T" "Current Data" and then select "Shift Position", "LR
Solenoid Duty" and "Underdrive Solenoid Duty" as shown.
10. Start the engine and move the shift lever between Neutral, Drive and Reverse, stopping 3-5
seconds in each gear.
11. Select "Record shown" at the top right of the screen. GDS will record up to 10 minutes data
prior to selecting "Record".
12. Select "PC Record" (top left of screen), then save file.
13. Select "Flight Record" and "Data Review", select the vehicle and open the file.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed
Reverse or Drive Engagement > Page 3568
Data, 1mm:
Flight Rfinnrd IIJIJ'I-
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14. Select "Items List" (top right of screen), then select "Shift Position", "LR Solenoid Duty" and
"Underdrive Solenoid Duty".
16. Move the cursor to the start of the shift and "Left click".
17. Move the cursor to the end of the shift and "Right Click".
18. Read the Low & Reverse solenoid engagement time on the top right of the screen. If the P-R
shift requires more than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle
and follow TSB 06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The LR solenoid elapsed time is important; the shape of the graph is not.
MEASURE PARK TO DRIVE ENGAGEMENT TIME:
19. Select "Flight Record" and "Data Review", select the vehicle and open the file.
20. Select "Items List" (top right of screen), then select "Shift Position LR Solenoid Duty" and
"Underdrive Solenoid Duty".
22. Move the cursor to the start of the shift and "Left click".
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-40-009-1 > Sep > 07 > A/T - Harsh/Delayed
Reverse or Drive Engagement > Page 3569
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NDTE: Warranty Claim requlrea Input cf DTG ccclea an all claims ualng Hl-Scan
cr GEE cperatiene. H' nc DTL": cede ie identified by the Hi-ecan er GDS,
enter Fflflflfl aa a Scan cl Teat Code on the Warranty Claim and attach
plintcut frcrn the Hi-acan er GDS tn the Repair Grder.
NDTE: Frintcuta must be attached to all Repair Drdars. Repalr Orders wlthcut
attached printcuts are subject tc chargeback.
23. Move the cursor to the end of the shift and "Right Click".
24. Read the UD engagement time on the top right of the screen. If the P-D shift requires more
than 2.2 seconds, exchange a PCM or TCM from a properly operating vehicle and follow TSB
06-40-005, "Reset and Relearn Adaptive Values":
NOTE:
The UD solenoid elapsed time is important; the shape of the graph is not.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > tnt1660906-03 > Sep > 06 > A/T, Engine Controls -
ECM/TCM Reset/Relearn Procedure
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Engine Control Module: All Technical Service Bulletins A/T, Engine Controls - ECM/TCM
Reset/Relearn Procedure
MODEL: All
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This article provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. After the
following repairs have been completed, the PCM/TCM adaptive values must be reset in order to
provide optimum shift quality:
Adaptive values must be reset using procedure # 1 or # 2 according to model and model year (MY)
as shown below.
VEHICLES AFFECTED:
^ All
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P."
^ Select vehicle
press "ENTER"
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
NOTE:
Adaptive learning does not occur below the ATF temperature range shown.
WARRANTY INFORMATION:
4 —
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Engine Control Module: All Technical Service Bulletins Engine Controls - ECU Reprogramming
Procedure
Reprogramming
This issue of TechNet Times focuses on reprogramming. In the current Hyundai service
environment, reprogramming can be accomplished with the Hi-Scan Pro or Hyundai's new Global
Diagnostic System (GDS). We begin here with an overview of the process of reprogramming the
ECU as performed using the GDS on a 2006 Azera that experiences a 1-2 shift hesitation under
wide open throttle operation when cold. As with most GDS features, you must select the model,
year and system in order to get started. You can manually enter the information by selecting
drop-down box options or, if the vehicle is a 2005 or newer model, you can enter the VIN and the
GDS will determine that information for you. Once the vehicle has been identified, select "ECU
Upgrade" located under the "Vehicle SW Management" tab. (See Figure 1.) Note: The Vehicle
Communication Interface (VCI) connects to the vehicle via the Data Link Connector (DLC); and the
VCI must be connected to the GDS PC using the USB connection. (Some other GDS functions
allow for wireless communication between the VCI and GDS PC.)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 3580
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The FCU Upgrade screen will appear. Select "Auto Mode." (See Figure 2.) The GDS will prompt
you to make sure that you have connected the VCI to the DLC and turned on the VCI power. (See
Figure 3.) After making sure, click "OK."
A window will appear to alert you that the GDS is "ROM ID Reading." During this time, the GDS will
check for available reprograms for the vehicle's FCU. If any reprograms are found, the ROM ID will
be listed in the "Current ROM ID" window. The "Current ROM ID" window shows the existing status
of programming in the FCU. Note: If the ROM IDs match, the ECU already has the latest
reprogramming or your GDS unit needs to have the latest updates installed. Refer to the chart on
page 5. The TCM ID column lists the latest ID for each condition. Go to the right edge of the
"Upgrade Event" window and click on the down arrow. Available upgrade events will be displayed
in a drop down box. When you select one, the "Upgrade" button will appear in the center of your
screen. (See Figure 4.)
After you have selected the event, click "Upgrade," you will be asked to confirm that you want to
upgrade. Then, you will be prompted to wait while everything is verified. If there is a corresponding
TSB for the upgrade, another pop-up will give you the option to recall it and familiarize yourself with
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 3581
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Once programming begins, the screen will display a status bar which monitors the reprogramming
process. (See Figure 5)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 3582
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When the reprogramming has finished and the status bar reads "100%," another pop-up will direct
you to turn the ignition off for 10 seconds and turn it back on. When you click "OK" a second
pop-up will prompt you to reset the automatic transaxle adaptive learning values. Note: Do not do
any other activity with your GDS until the reprogramming is completed. (See Figure 6.) To reset the
Automatic Transaxle Adaptive Learning Values, click the "System" button toward the top of the
screen. The "GDS System Search" screen will appear and from it select "A/T." Then, choose the
"Resetting A/T Values" option. When the "Resetting A/T Values" screen (See Figure 7) appears,
click on "reset." A confirming pop-up will ask, "Are you sure?" Click "OK" and the values will be
reset and reprogramming will be complete.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > tnt1630506-01 > May > 06 > A/T Controls -
PCM/TCM Reset/Relearn Adaptive Values
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Engine Control Module: All Technical Service Bulletins A/T Controls - PCM/TCM Reset/Relearn
Adaptive Values
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. Here are the procedures
necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. Afier the following
repairs have been completed, the PCM/TCM adaptive values must be reset in order to provide
optimum shift quality:
HI-SCAN PROCEDURE:
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > tnt1630506-01 > May > 06 > A/T Controls -
PCM/TCM Reset/Relearn Adaptive Values > Page 3588
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man: an. NM 21112 MT-e
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2.1 Hm Ema W —
NOTE:
Adaptive learning does not occur below the ATF temperature range shown in next column:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-40-005 > Mar > 06 > A/T Controls - Reset and
Relearn Adaptive Values
2.
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Engine Control Module: All Technical Service Bulletins A/T Controls - Reset and Relearn Adaptive
Values
Group: TRANSAXLE
Number: 06-40-005
Model: ALL
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
W WWW
WWW
2m-
2005 MT-v
2005 MY-
BIG! IE EPIIII
THREE! I DELI RPI'I
HIGI I'IE BTH'I'E' I DIE
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-40-005 > Mar > 06 > A/T Controls - Reset and
Relearn Adaptive Values > Page 3594
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR" "ACCEL. POS. S". or "ACCEL PEDAL 1
VOLT", depending on model).
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi- Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the accelerator pedal steady at a throttle position
sensor value of 1.45-1.75v during several 1-2-3-4 upshifts. Repeat until normal gear transitions
occur.
NOTE:
Adaptive learning does not occur below the ATF temperature range previously shown.
WARRANTY INFORMATION:
: ; »
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Engine Control Module: All Technical Service Bulletins A/T - TCM/ECM Adaptive Value
Rest/Relearn Procedure
Group:AUTOMATIC TRANSAXLE
Number: 11-AT-008
Model: ALL
This bulletin supersedes TSB 10-AT-Oil to include 2011~ Elantra, 2012~ Accent and Genesis
Sedan.
After replacing a transaxle or reprogramming the PCM/TCM, follow this procedure to reset and
relearn the adaptive learning to improve shift quality.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
arm: jam- m
1.1mm
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[Gene-II ASL. Equal MEL, and Gene-II Camp-e 3.0L wlfl'u 2F Inn-mlnlun].
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
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6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified TPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > 11-AT-008 > Apr > 11 > A/T - TCM/ECM Adaptive Value
Rest/Relearn Procedure > Page 3603
Adaptive learning occurs only within the ATF temperature ranges shown.
WARRANTY INFORMATION:
“Mum m m F m
System
Sula-ct Sygtnm SEI acted System
“mamaHQ —
§@@@@@g
_ 7 —..:a__l—l-
Engine Control Module: All Technical Service Bulletins A/T Controls - Resetting PCM/TCM
Adaptive Values
Number: 10-AT-Oil
Model: ALL
Subject
This bulletin supersedes TSB 09-AT-002-1 to include Equus and Sonata HEV
CAUTION:
After replacing a transaxle or reprogramming the PCM/TCM, to improve the shift quality condition,
follow this procedure to reset and relearn the adaptive learning.
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the PCM/TCM adaptive values.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
HDTE: * Clear BAH Laarnahla sum: only If Mmhatrunlu {valva may: I: filfihfll’lflifl mam Inufllfl mun
[El-fillil 1.6L. Equus LEI. and GHI-flil- Gnupl 3.5L with 2F trim-ninth}.
NOTE:
GDS must be used to reset the adaptive learning for the following vehicles.
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
m m m w w m fl n
' 1 ? t 'l-5 I."
6. Drive the vehicle until the ATF temperature is within the range shown.
7. Request an assistant to monitor the GDS. Accelerate from a stop at the specified IPS
specification while the transmission shifts through gears
1-2-3-4-5-6 and decelerate slowly to a stop. Stop for 5 seconds. Repeat 5 times.
NOTE:
CAUTION:
8. Perform several sequential downshifts (5-4, 4-3, 3-2 and 2-1) at small to moderate throttle
openings.
9. Perform several skip shifts (6-4, 5-3, 5-2, 3-1, etc.) at moderate to large throttle openings.
10. With the vehicle stopped, move the shift lever from P to N to D and back, stopping 3~5 seconds
in each gear. Repeat 5 times.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > 10-AT-011 > Aug > 10 > A/T Controls - Resetting
PCM/TCM Adaptive Values > Page 3611
NOTE:
Adaptive learning occurs only within the ATF temperature ranges shown:
WARRANTY INFORMATION:
Normal warranty applies
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > tnt1660906-03 > Sep > 06 > A/T, Engine Controls -
ECM/TCM Reset/Relearn Procedure
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m m LEI. IEHEIE-E'WE M'f m5 [kW-
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2:1 _ 19m~2mn M 3115 I'm—-
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Engine Control Module: All Technical Service Bulletins A/T, Engine Controls - ECM/TCM
Reset/Relearn Procedure
MODEL: All
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This article provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. After the
following repairs have been completed, the PCM/TCM adaptive values must be reset in order to
provide optimum shift quality:
Adaptive values must be reset using procedure # 1 or # 2 according to model and model year (MY)
as shown below.
VEHICLES AFFECTED:
^ All
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P."
^ Select vehicle
press "ENTER"
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
NOTE:
Adaptive learning does not occur below the ATF temperature range shown.
WARRANTY INFORMATION:
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Engine Control Module: All Technical Service Bulletins Engine Controls - ECU Reprogramming
Procedure
Reprogramming
This issue of TechNet Times focuses on reprogramming. In the current Hyundai service
environment, reprogramming can be accomplished with the Hi-Scan Pro or Hyundai's new Global
Diagnostic System (GDS). We begin here with an overview of the process of reprogramming the
ECU as performed using the GDS on a 2006 Azera that experiences a 1-2 shift hesitation under
wide open throttle operation when cold. As with most GDS features, you must select the model,
year and system in order to get started. You can manually enter the information by selecting
drop-down box options or, if the vehicle is a 2005 or newer model, you can enter the VIN and the
GDS will determine that information for you. Once the vehicle has been identified, select "ECU
Upgrade" located under the "Vehicle SW Management" tab. (See Figure 1.) Note: The Vehicle
Communication Interface (VCI) connects to the vehicle via the Data Link Connector (DLC); and the
VCI must be connected to the GDS PC using the USB connection. (Some other GDS functions
allow for wireless communication between the VCI and GDS PC.)
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Bulletins > All Other Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 3622
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The FCU Upgrade screen will appear. Select "Auto Mode." (See Figure 2.) The GDS will prompt
you to make sure that you have connected the VCI to the DLC and turned on the VCI power. (See
Figure 3.) After making sure, click "OK."
A window will appear to alert you that the GDS is "ROM ID Reading." During this time, the GDS will
check for available reprograms for the vehicle's FCU. If any reprograms are found, the ROM ID will
be listed in the "Current ROM ID" window. The "Current ROM ID" window shows the existing status
of programming in the FCU. Note: If the ROM IDs match, the ECU already has the latest
reprogramming or your GDS unit needs to have the latest updates installed. Refer to the chart on
page 5. The TCM ID column lists the latest ID for each condition. Go to the right edge of the
"Upgrade Event" window and click on the down arrow. Available upgrade events will be displayed
in a drop down box. When you select one, the "Upgrade" button will appear in the center of your
screen. (See Figure 4.)
After you have selected the event, click "Upgrade," you will be asked to confirm that you want to
upgrade. Then, you will be prompted to wait while everything is verified. If there is a corresponding
TSB for the upgrade, another pop-up will give you the option to recall it and familiarize yourself with
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Bulletins > All Other Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 3623
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Once programming begins, the screen will display a status bar which monitors the reprogramming
process. (See Figure 5)
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > tnt1640706-01 > Jul > 06 > Engine Controls - ECU
Reprogramming Procedure > Page 3624
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When the reprogramming has finished and the status bar reads "100%," another pop-up will direct
you to turn the ignition off for 10 seconds and turn it back on. When you click "OK" a second
pop-up will prompt you to reset the automatic transaxle adaptive learning values. Note: Do not do
any other activity with your GDS until the reprogramming is completed. (See Figure 6.) To reset the
Automatic Transaxle Adaptive Learning Values, click the "System" button toward the top of the
screen. The "GDS System Search" screen will appear and from it select "A/T." Then, choose the
"Resetting A/T Values" option. When the "Resetting A/T Values" screen (See Figure 7) appears,
click on "reset." A confirming pop-up will ask, "Are you sure?" Click "OK" and the values will be
reset and reprogramming will be complete.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > tnt1630506-01 > May > 06 > A/T Controls - PCM/TCM
Reset/Relearn Adaptive Values
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Engine Control Module: All Technical Service Bulletins A/T Controls - PCM/TCM Reset/Relearn
Adaptive Values
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. Here are the procedures
necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM. Afier the following
repairs have been completed, the PCM/TCM adaptive values must be reset in order to provide
optimum shift quality:
HI-SCAN PROCEDURE:
1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown below.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR",
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi-Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the
accelerator pedal steady at a throttle position sensor value of 1.45~1.75v during several 1-2-3-4
upshifts.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > tnt1630506-01 > May > 06 > A/T Controls - PCM/TCM
Reset/Relearn Adaptive Values > Page 3630
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NOTE:
Adaptive learning does not occur below the ATF temperature range shown in next column:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > 06-40-005 > Mar > 06 > A/T Controls - Reset and
Relearn Adaptive Values
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Engine Control Module: All Technical Service Bulletins A/T Controls - Reset and Relearn Adaptive
Values
Group: TRANSAXLE
Number: 06-40-005
Model: ALL
DESCRIPTION:
The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to
compensate for normal clutch wear over the life of the transaxle. This bulletin provides the
procedures necessary to reset (erase) and "relearn" the adaptive values in the PCM/TCM.
After the following repairs have been completed, the PCM/TCM adaptive values must be reset in
order to provide optimum shift quality:
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1. Turn the Ignition key to the "ON" position (do not start engine) and move the shift lever to "P".
^ Select vehicle
NOTE:
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > 06-40-005 > Mar > 06 > A/T Controls - Reset and
Relearn Adaptive Values > Page 3636
After the adaptive values have been reset (erased), an "adaptive learning" procedure must be
completed as shown.
3. Attach a Hi-Scan Pro or GDS and select "Engine" menu, "Current Data" menu and throttle
position sensor in volts ("THROTTLE POS. SENSOR" "ACCEL. POS. S". or "ACCEL PEDAL 1
VOLT", depending on model).
4. Drive the vehicle until the ATF temperature is within the temperature range shown.
5. Request an assistant to monitor the Hi- Scan while accelerating the vehicle at small throttle
openings (approximately 25-30% throttle). Hold the accelerator pedal steady at a throttle position
sensor value of 1.45-1.75v during several 1-2-3-4 upshifts. Repeat until normal gear transitions
occur.
NOTE:
Adaptive learning does not occur below the ATF temperature range previously shown.
WARRANTY INFORMATION:
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Page 3638
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Page 3639
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Information and Instructions > Page 3642
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Information and Instructions > Page 3645
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Information and Instructions > Page 3646
35
3
Symbols Part 1
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3647
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3648
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Information and Instructions > Page 3651
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3653
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3654
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3655
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3656
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3657
DDHNEGTDH [1'3144-1]
§
I
H
$
t"!
3 .1.
D
2
2
Dmrlntion fiuflnlflltl tu
M
W W Cantu!
Fur Autatrunsaula Gmh'ul
Fur W e : Bantu!
Fur Autuh'msalda Gmtml
Fur Autuhmatuda Cmu'ul
Glutuh Switm uiunal input Gruiau Glufl'l Pad! Fuuflhn Snitch
Fur m m : Gmuul
Fur Hummus curmul
— l — _ — F — ' — F —
i7
n
Air candltlener Pl'lllul'l- Banner signal input
i
n
n
5'5"" ""3"“
AI" Cmdltmer Praaatl'a Samar. Fewer Steerhg
Praaaura SHEET {PEPE}
Dismiplion
.. ‘
55 Honour Fowsr Supply (+514!) A" Emmagiflflflglfiflw Fowsr Elfifi'll'lii
n For m u m : Contml
n Throtlis Fsslflon Bansor lions! iPWM} nullaut ABS Cultist luloduls. ESP Control Illloduls
Bruise 'MAIN' Ilmp oonl'ui output Gluiss 'MAIN' La'rlp
u Fusl Pump Finlay oonuoi outpll Fusi Plunp Relay
- 71 Variable Intake Sobnoid Volvo oontroi milput Unishto inislss Soisnnid WIS] 1|Ill'slus
Immohillzsr lsmp oonlrol output ln'lrlohlllzsr Lamp
For m m Gondoi
_TH Puma Bouillol Buimuid “also mnh'oi output Furgo Gontroi tnoid m {FGB‘U‘}
'4
to
Whool Speed Ssnsor [Low] signal input inmost Eposd Emsor Mfijrmihout ABSJ'ESF']
t s l Eposd Sensor [High] signal input t s l Speed Esnsor UHSSIMflhout ABSIESF]
E
CI
:1
E
:a
G
2
E
—I.
é
”I
2
Samuel-d ta
EI'S lulatar H aantral aulptn EI'G Matar [In ETl'; Maaula}
n Mmlhld Ahaaltla Fraaaurae Sanaar signal Imut Mmllalrl Abaaluta Fraaaura Samar {MAPS}
n Far Autatranaaada Sana-at
_ Samfl'rafl Faailian Samar {Bark 2] graunrl Camshaft Faalian Samar {SHIPS} [Elmlr 2]
n Samahal‘lllan SanaarlSanl: 1] annual! Camshaft Faallan SanaarlSHPSHSanH]
n Imitian Sat [Cylindar #Sl aantral aulaul Innllian Sal {WIinrlar #S}
u
u Sranlratflt Paalllan Sanaar [l-Igh] alnnal Input alumna F'aalflan Sanau' [SHIPS]
Far W Em m
m
E - HaatadflxymnSl'raarEBmkEISamarflgaund HaataarganSanaarfl-IDESJMmHElSanaaH
l — fl
u l-IaalaaayganSa'laarmmlrElSanaarflywnd HaaladyganSanaartHDESlmmlrzlSanaarE
n mama mammal: 1 15m “ma Haatad oxygan Sanaarll-IDESHSEIIIH lSanaar‘l
n Haatarl Own Sanaar [Bank 1 .-' Sanaar 2] graund Haalarl Oxygen Sanaar [HESS] [Bank 1 l' Sanaar 2]
Gamahaft Fnaiflm Sanaar [Emit 1] mar aupphr Gamahfl't Palltlan Samar [SHIPS] [Bank 1]
Enma Saatmt Tarnparatura Sanaar nraunll Ennlna ll."laalant Tarnpalatlra Sanaar [ESTS]
Manlhld-Abaaluta Fraaaura Sanaar {MP5}.
CWT S11 Tan'param Sanaar {DIS}
Bhaaala Graund
_
Chaaala Grauna
_ _ _ . — .
PCM Terminal Function - Connector (C144-2) Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 3661
— r — I - — — u' —
Deteripflan Canneated ta
Chassis Grauna
Patter gauntl Ct1easleCratl1d
Fewer yet-1a Illitt Emma
Ianillan Call [Cyllntllr #41aantral autput lgn‘tlim Cail [Cylinder #4}
Crankfl'tdt Paeilien Sertttt'n' new] signal haul Crankshaft Pattillan Senear {CHIPS}
42 Far Autah'artaaxla Central
n
n
Far manna-axle Central
Far mmaanwae Canaan
n
u
Far mtalranaeatle Central
m e w sat-mar [Bank 2 F EH15" l-Ieetea Oxygen Senaar {HC25} [nut 21' Senlar 2}
u
n
Hnaalt Senear {HS}#2 [l-llgn] signal Input
HI‘lDC-I'L Belem [HS]: #2 [Law] Signal injlul.
HHCCII. ESHSCI" [H5] #2 [Huh]
Hllufllt EIII'IIEI'LI (H3) #2 [Lulu]
n
u
Sneak Samar {KS}#1 [La-HI signal input
lineal-t Senear {HS} #1 [High] elgrtel Input
Knaalt Sensor {K8} #1 [Lair]
Knack Seneer [KS] #1 [nh]
n 53
Thratlle Paeltlan Sertaer #2 algnfl input
Thrntlle Paeit‘nn Set-tater #2 nutmd
Thratlle Paetlian Senaar {FPS} #2
11'trettle Punillm Serteer {11:5} #2
59 Far nutattaneaztle Central
lgnltlan Cail {Cfi'tdar #2} ant-that auttaut Inritiart Call {Cyli'ttler #2]
CWT Cil Canaal Viva [Benlt 2] aanlral autput CWT Cll Cantral Valve {CCU} [Bantu 2]
CWT Ci t a fl fl l t _1]_aarttr_1_.'tl_eutpll_t CWT CII Emtral Valve {CCU} [Berlt 1]
inhaler {entree #2] aanlral «:11t 5' Mtcfiwfit “ _ —' ’—
.mmmmanna mm
fulfil: WEE“ EBI'IIDT [BEBE 2 .l' SEMI"
1] HSHIHI' aanlml output Hm Dxraan 5mlHflEE-l [Bank 2 t E'tenltnr 1]
ummmmm: mm: mm
as mammal-marmmw
_ T1
l-lettled Oxygen Smear [Emit 1 lSansar
uducripflnn ‘ -. £ 1 : a tr.-
lnjm {Gylhder #1} mntml uulput njautm' { t u ' #1}
5'1““ mam “ [Bank 2 I Samar Hunted Oxygen “(Heisman-1:2 {Sunni}
mmnsmww w
Hilary
Imfllnn Call [may #3) annual nuiput Innlflun col {Cyllndar #3}
mififln Gail [Gym #5} animal nutput Ignlflm Cal {Cyllntlar #5}
__ ggnrHun Call [cum #1} cmtml mam“ Ignfllun Gui {Cylinder #1}
EDHHEETDR [mu-1]
' Fin
q
i
Ha.
E‘
II 2nd CM [High]
H 2!“ CAN [LN]
H Fur Autuflansaxla Cmtnl
II FIJI Autulmnsaxla Gml
E
Hinh: Bum
2
m m load aimai input PULSE Lulu: Max. 1.
140 -- mm:
m W“ W ““1"" - _ -
E m m W m mm “ m
iilliili
-
null.
fl
Fur mmuamxla Gmimi
i
Emil: pedal
21 Baum slgnal Input
E
3
i3
I Fm Marla-urn Cantu!
Laval insult
E
5
2? Diagnaafla Dal: Lila {Ii-Lina} HlflT lulh
m u m
E
m
E
Ba'llarjqI vallaua supply altar mail ralay
'2 E E
Battarr unltaua amplyafiarmaln ralagllr
3
cm
E
aE2
E
E
El
w
4? Hana Air Fll'fll' Samar alpnil lrput — -
3.0mm
— —
”WWW “ m
1%
Pasilian Samar _|
. :13 ~ aw
n
Aaaalaralar
#2 m w
Far Pulatansafla t ' a l
w “”9 m -
Waa 'SET' lamp aanll'al autput
.5
E
'2
52 1lnI'IIlIl-Iiala speed almal hput 1Inl'hlhiala running
#1 algnal Input
-l
5’
Aaaalaralar Pauilian Emaar
'U'l
W
#1 gaund
3;
IHEH'
a
ar Vraf
Law: Max. 0.5?
53
Malfunalian lndlaaliar Lamp {MIL} Hlm: Battery Wilma 4
aantral aulput MIL a."
g
.2'
3
if."
i
Dun-inflon Gundltim
Hill
I
g
-57'
~= E
g5
5i
H
m
Tfluttla Fultlun Samar almal
{PWMIWIPIII
I
FF
TI}
E:E
a
E
I 1" I W "I”. Emu m
annual mm Iranllva
T
-4 1-1 -.I -.1
E5
ia
:Imal input
Wheat Speed Samar [Hluh]
El
D
Elana [13:51!
CDMHECTDR [0144-2]
:2: mm
i
E
E
E
ETC: Habit H m Dub"!
Pin
Ha.
2 2 —
Ella-NEH“
%“mu
flE—Ennnnmmmgm
4Garqshaflfulflhn Bum [Bank
.
c m Podium 5 m [Bank
1] signs! Input
.
r m 1] yuund
I'llltfld Oxygen 53m [Bank 2
J'Eansnr 2] [ 1 e
:
Haaladflxmnfiammmm
Faerunrflg'wnd
I-laaladygaalurlflmH
Imamnd
Man; H.511?
Crflfllfill'll'fl Ila-Him E m
.
mi. —
.
PCM Terminal Input/Output Signal - Connector (C144-2) Part 2
"
3
l
P
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
.
Information and Instructions > Page 3669
m
a
I
g
Daaarlptlan
I
Thralfla Paalflan Samar #1
ll tipnal Input
Ill-ml- Wa
.
WWI-1SanaarlH Ermine Hmninn
.
I
n
—
.
finaakBanaarmgjpzfl-liw
i.
El
walnut {KB} #2 [Lou]
I-lfl-I
|
Ilpnal Irumt
limd Input I m
H
U
'55 ThratflaFaIiflmsanaarfln‘aund
59 FarAutat'anaafllacanlral
WWW
. LEV 11w
am a: aunt-a1 nah-a {Bank
2] aaniral autput
“In nil-amine the 13H:
Tm
m
n
m
m
m
Ha.
High: B M W “ 13.3“
m
Vpaak: m. HEN
a. m
Heated Men Eenaal' [Bank 2 J"
TI
High: Batterytfaflane
Lilli: Matt. LEV
.
Ini-eeter [wilder #1} animal autput
Vpeak: ”Hal. BEN
mm
mm
W
W
m
m
m
.
.
wmwMmm
a:
T5 _
W _
_ - m: — — -
m _ — m — m
an: flux. 2*:
m
mflfi'mn}
mm numut
1. TEST PCM GROUND CIRCUIT: Measure resistance between PCM and chassis ground using
the backside of PCM harness connector as PCM
2. TEST PCM CONNECTOR: Disconnect the PCM connector and visually check the ground
terminals on PCM side and harness side for bent pins
3. If problem is not found in Step 1 and 2, the PCM could be faulty. If so, replace the PCM with a
new one, and then check the vehicle again. If the
vehicle operates normally then the problem was likely with the PCM.
4. RE-TEST THE ORIGINAL PCM : Install the original PCM (may be broken) into a known-good
vehicle and check the vehicle. If the problem
occurs again, replace the original PCM with a new one. If problem does not occur, this is
intermittent problem (Refer to INTERMITTENT PROBLEM PROCEDURE in BASIC INSPECTION
PROCEDURE). See: Computers and Control Systems/Testing and Inspection/Component Tests
and General Diagnostics/Electronic Component Inspection Procedures
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection >
Component Tests and General Diagnostics > Page 3674
DDHNEGTDH [1'3144-1]
§
I
H
$
t"!
3 .1.
D
2
2
Dmrlntion fiuflnlflltl tu
M
W W Cantu!
Fur Autatrunsaula Gmh'ul
Fur W e : Bantu!
Fur Autuh'msalda Gmtml
Fur Autuhmatuda Cmu'ul
Glutuh Switm uiunal input Gruiau Glufl'l Pad! Fuuflhn Snitch
Fur m m : Gmuul
Fur Hummus curmul
— l — _ — F — ' — F —
i7
n
Air candltlener Pl'lllul'l- Banner signal input
i
n
n
5'5"" ""3"“
AI" Cmdltmer Praaatl'a Samar. Fewer Steerhg
Praaaura SHEET {PEPE}
Dismiplion
.. ‘
55 Honour Fowsr Supply (+514!) A" Emmagiflflflglfiflw Fowsr Elfifi'll'lii
n For m u m : Contml
n Throtlis Fsslflon Bansor lions! iPWM} nullaut ABS Cultist luloduls. ESP Control Illloduls
Bruise 'MAIN' Ilmp oonl'ui output Gluiss 'MAIN' La'rlp
u Fusl Pump Finlay oonuoi outpll Fusi Plunp Relay
- 71 Variable Intake Sobnoid Volvo oontroi milput Unishto inislss Soisnnid WIS] 1|Ill'slus
Immohillzsr lsmp oonlrol output ln'lrlohlllzsr Lamp
For m m Gondoi
_TH Puma Bouillol Buimuid “also mnh'oi output Furgo Gontroi tnoid m {FGB‘U‘}
'4
to
Whool Speed Ssnsor [Low] signal input inmost Eposd Emsor Mfijrmihout ABSJ'ESF']
t s l Eposd Sensor [High] signal input t s l Speed Esnsor UHSSIMflhout ABSIESF]
E
CI
:1
E
:a
G
2
E
—I.
é
”I
2
Samuel-d ta
EI'S lulatar H aantral aulptn EI'G Matar [In ETl'; Maaula}
n Mmlhld Ahaaltla Fraaaurae Sanaar signal Imut Mmllalrl Abaaluta Fraaaura Samar {MAPS}
n Far Autatranaaada Sana-at
_ Samfl'rafl Faailian Samar {Bark 2] graunrl Camshaft Faalian Samar {SHIPS} [Elmlr 2]
n Samahal‘lllan SanaarlSanl: 1] annual! Camshaft Faallan SanaarlSHPSHSanH]
n Imitian Sat [Cylindar #Sl aantral aulaul Innllian Sal {WIinrlar #S}
u
u Sranlratflt Paalllan Sanaar [l-Igh] alnnal Input alumna F'aalflan Sanau' [SHIPS]
Far W Em m
m
E - HaatadflxymnSl'raarEBmkEISamarflgaund HaataarganSanaarfl-IDESJMmHElSanaaH
l — fl
u l-IaalaaayganSa'laarmmlrElSanaarflywnd HaaladyganSanaartHDESlmmlrzlSanaarE
n mama mammal: 1 15m “ma Haatad oxygan Sanaarll-IDESHSEIIIH lSanaar‘l
n Haatarl Own Sanaar [Bank 1 .-' Sanaar 2] graund Haalarl Oxygen Sanaar [HESS] [Bank 1 l' Sanaar 2]
Gamahaft Fnaiflm Sanaar [Emit 1] mar aupphr Gamahfl't Palltlan Samar [SHIPS] [Bank 1]
Enma Saatmt Tarnparatura Sanaar nraunll Ennlna ll."laalant Tarnpalatlra Sanaar [ESTS]
Manlhld-Abaaluta Fraaaura Sanaar {MP5}.
CWT S11 Tan'param Sanaar {DIS}
Bhaaala Graund
_
Chaaala Grauna
_ _ _ . — .
PCM Terminal Function - Connector (C144-2) Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection >
Component Tests and General Diagnostics > Page 3678
— r — I - — — u' —
Deteripflan Canneated ta
Chassis Grauna
Patter gauntl Ct1easleCratl1d
Fewer yet-1a Illitt Emma
Ianillan Call [Cyllntllr #41aantral autput lgn‘tlim Cail [Cylinder #4}
Crankfl'tdt Paeilien Sertttt'n' new] signal haul Crankshaft Pattillan Senear {CHIPS}
42 Far Autah'artaaxla Central
n
n
Far manna-axle Central
Far mmaanwae Canaan
n
u
Far mtalranaeatle Central
m e w sat-mar [Bank 2 F EH15" l-Ieetea Oxygen Senaar {HC25} [nut 21' Senlar 2}
u
n
Hnaalt Senear {HS}#2 [l-llgn] signal Input
HI‘lDC-I'L Belem [HS]: #2 [Law] Signal injlul.
HHCCII. ESHSCI" [H5] #2 [Huh]
Hllufllt EIII'IIEI'LI (H3) #2 [Lulu]
n
u
Sneak Samar {KS}#1 [La-HI signal input
lineal-t Senear {HS} #1 [High] elgrtel Input
Knaalt Sensor {K8} #1 [Lair]
Knack Seneer [KS] #1 [nh]
n 53
Thratlle Paeltlan Sertaer #2 algnfl input
Thrntlle Paeit‘nn Set-tater #2 nutmd
Thratlle Paetlian Senaar {FPS} #2
11'trettle Punillm Serteer {11:5} #2
59 Far nutattaneaztle Central
lgnltlan Cail {Cfi'tdar #2} ant-that auttaut Inritiart Call {Cyli'ttler #2]
CWT Cil Canaal Viva [Benlt 2] aanlral autput CWT Cll Cantral Valve {CCU} [Bantu 2]
CWT Ci t a fl fl l t _1]_aarttr_1_.'tl_eutpll_t CWT CII Emtral Valve {CCU} [Berlt 1]
inhaler {entree #2] aanlral «:11t 5' Mtcfiwfit “ _ —' ’—
.mmmmanna mm
fulfil: WEE“ EBI'IIDT [BEBE 2 .l' SEMI"
1] HSHIHI' aanlml output Hm Dxraan 5mlHflEE-l [Bank 2 t E'tenltnr 1]
ummmmm: mm: mm
as mammal-marmmw
_ T1
l-lettled Oxygen Smear [Emit 1 lSansar
uducripflnn ‘ -. £ 1 : a tr.-
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection >
.
Component Tests and General Diagnostics > Page 3686
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VIN (Vehicle Identification Number) is a number that has the vehicle's information (Maker, Vehicle
Type, Vehicle Line/Series, Body Type, Engine Type, Transmission Type, Model Year, Plant
Location and so forth). When replacing an PCM, the VIN must be programmed in the PCM. If there
is no VIN in PCM memory, the fault code (DTC P0630) is set.
CAUTION: The programmed VIN cannot be changed. When writing the VIN, confirm the VIN
carefully.
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6. Turn the ignition switch OFF; and then turn ON. 7. Verify the programmed VIN in the PCM
memory.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3695
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3700
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3703
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3706
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3707
35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3708
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3709
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3711
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3712
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3713
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3714
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3715
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3716
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 3717
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
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LJ._I'
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3721
311T
1331- B aaaa 1 1 5
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor: > 10-EE-002 > Jul > 10 > Engine Controls -
MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor: > 07-36-006 > Sep > 07 > Engine Controls -
Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - Low Power/MIL ON/DTC
P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
j
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Llfll 'l— Fufl 'l'I-I-llfli 4.! fl
III-I 'I‘Il-Fufl'I'h-ld!‘ u I
lul'll'flfl Fufl Iii-EH! 1%! #-
Hlflflllflifillfllhl-t fl..- Hll i I g
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Example GDS DTC screen shown.
DP CASUAL CUBE
firljflDEL 01’ NAME TIME PART I
NATURE CAUSE
327m 3mm
msmnw DIAGHDEIE
3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Accelerator Pedal Position Sensor: > 10-EE-002 > Jul > 10 > Engine
Controls - MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Accelerator Pedal Position Sensor: > 07-36-006 > Sep > 07 > Engine
Controls - Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - Low
Power/MIL ON/DTC P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
j
a Frau“ Frlma j
m m m m m : m u
l m h | II'h'lTl-fl
Human—um cum -
n nun-1mm I.- I
‘ thumb: luflnhflnflmnflihm II 'f
:ITSEI Sill-ITE- nan-mun I.- I
Llfll 'l— Fufl 'l'I-I-llfli 4.! fl
III-I 'I‘Il-Fufl'I'h-ld!‘ u I
lul'll'flfl Fufl Iii-EH! 1%! #-
Hlflflllflifillfllhl-t fl..- Hll i I g
I - . ... .. I. ll”- -
Inmmm M "
HEU EEEE null -nan : W
Example GDS DTC screen shown.
DP CASUAL CUBE
firljflDEL 01’ NAME TIME PART I
NATURE CAUSE
327m 3mm
msmnw DIAGHDEIE
3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 3753
.m.
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 3755
311T
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Overview
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 3756
No.53
3'. ..
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i
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 3757
DEECRIPTIDH emu:
Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 3758
DESCRIPTIDN mm
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SPECIFIEATIDH
Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
Specification
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 3759
SCHEHATIE DMHAH
[macurr DMEHMJ]
“ —
“ — —
Schematic Diagram
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications
Detail
'-
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page
3764
311T
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page
3765
"il' '
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions
THEE: -
. I . . . I . l H l . . . l H
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3768
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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tha color uf 1h: calm uf
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unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3771
E .
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3772
35
3
Symbols Part 1
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3773
.—
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Symbols Part 2
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3774
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
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SPECIFICATION
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DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
Specification
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Component Locations
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Component Locations > Page 3791
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Component Locations > Page 3792
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- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Information and Instructions > Page 3795
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
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Symbols Part 1
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Information and Instructions > Page 3800
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Information and Instructions > Page 3801
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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3810
DESCRIPTION Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft
position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects
the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which out- put voltage changes when magnetic field is made on the IC with
current flow. So the sequential injection of the 6 cylinders is impossible without CMPS signal.
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3811
DESCRIPTION Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft
position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects
the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which out- put voltage changes when magnetic field is made on the IC with
current flow. So the sequential injection of the 6 cylinders is impossible without CMPS signal.
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3812
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Information > Specifications > Page 3816
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Information > Specifications > Page 3817
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Information > Specifications > Page 3818
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Information > Specifications > Page 3819
DESCRIPTION
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
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Information > Specifications > Page 3820
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Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the
cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose
resistance changes with the temperature. The electrical resistance of the ECTS decreases as the
temperature increases, and increases as the temperature decreases. The reference 5 V in the
PCM is supplied to the ECTS via a resistor in the PCM.That is, the resistor in the PCM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the
ECTS changes according to the engine coolant temperature, the output voltage also changes.
During cold engine operation the PCM increases the fuel injection duration and controls the ignition
timing using the information of engine coolant temperature to avoid engine stalling and improve
driveablity.
Specification
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Schematic Diagram
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Page 3825
Detail
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Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
3
Symbols Part 1
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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3843
DESCRIPTION Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of
the most important sensors of the engine control system. If there is no CKPS signal input, fuel is
not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal.
This sensor is installed on transaxle housing and generates alternating current by magnetic flux
field which is made by the sensor and the target wheel when engine runs. The magnetic flux
increases when the protrusion of the target wheel is getting near to the sensor and does not
change in the most close position. When the protrusion becomes estranged from the sensor,
magnetic flux disappears and alternating current is generated. The target wheel consists of 58 slots
and 2 missing slots on 360 CA (Crank Angle).
.
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3844
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DESCRIPTION Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of
the most important sensors of the engine control system. If there is no CKPS signal input, fuel is
not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal.
This sensor is installed on transaxle housing and generates alternating current by magnetic flux
field which is made by the sensor and the target wheel when engine runs. The magnetic flux
increases when the protrusion of the target wheel is getting near to the sensor and does not
change in the most close position. When the protrusion becomes estranged from the sensor,
magnetic flux disappears and alternating current is generated. The target wheel consists of 58 slots
and 2 missing slots on 360 CA (Crank Angle).
Waveform
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3845
ECEEHATIG DIAGRAM
Schematic Diagram
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COMPONENTS m
Components
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Page 3853
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Page 3854
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Page 3855
DESCRIPTION enema
Description
The evaporative emission control system prevents hydrocarbon vapors from escaping from the fuel
tank into the atmosphere where they could form photochemical smog. Gasoline vapors are
collected in the charcoal canister. The Fuel Tank Pressure Sensor (FTPS) is installed on fuel pump
assembly and is an integral part of the evaporative monitoring system. The PCM monitors the
FTPS signal to detect vacuum decay and excess vacuum. The FTPS measures the difference
between the air pressure inside the fuel tank and outside air pressure to check the purge control
solenoid valve operation and for leak detection in the evaporative emission control system by
monitoring pressure and vacuum levels in the fuel tank during the purge control solenoid valve
operating cycles.
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Page 3856
DESCRIPTION enema
SPEEIFICATIDH
Description
The evaporative emission control system prevents hydrocarbon vapors from escaping from the fuel
tank into the atmosphere where they could form photochemical smog. Gasoline vapors are
collected in the charcoal canister. The Fuel Tank Pressure Sensor (FTPS) is installed on fuel pump
assembly and is an integral part of the evaporative monitoring system. The PCM monitors the
FTPS signal to detect vacuum decay and excess vacuum. The FTPS measures the difference
between the air pressure inside the fuel tank and outside air pressure to check the purge control
solenoid valve operation and for leak detection in the evaporative emission control system by
monitoring pressure and vacuum levels in the fuel tank during the purge control solenoid valve
operating cycles.
Specification
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Page 3857
SBHEHATIG MEAN!
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Schematic Diagram
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Page 3862
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Page 3863
DESCRIPTION EWEEGBJ:
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Description
DESCRIPTION Intake Air Temperature Sensor (IATS) is installed inside the Mass Air Flow Sensor
(MAFS) and detects the intake air temperature. To calculate precise air quantity, correction of the
air temperature is needed because air density varies according to the temperature. So the PCM
uses not only MAFS signal but also IATS signal. This sensor has a Negative Temperature
Coefficient (NTC) and its resistance is in inverse proportion to the temperature.
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Page 3864
DESCRIPTION EWEEGBJ:
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SPECIFICATION
Description
DESCRIPTION Intake Air Temperature Sensor (IATS) is installed inside the Mass Air Flow Sensor
(MAFS) and detects the intake air temperature. To calculate precise air quantity, correction of the
air temperature is needed because air density varies according to the temperature. So the PCM
uses not only MAFS signal but also IATS signal. This sensor has a Negative Temperature
Coefficient (NTC) and its resistance is in inverse proportion to the temperature.
Specification
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Page 3865
SCHEMATIG 0mm
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Schematic Diagram
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‘ _ _ — -
Detail
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> Page 3870
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> Page 3871
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Specification
DESCRIPTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine
damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the
V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is
applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the
knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing.
This sequential control can improve engine power, torque and fuel economy.
Item.......................................................................................................................................................
..............................................................Specification
Capacitance..........................................................................................................................................
..........................................................1,480 - 2,220 pF
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EPEL' IFEATI-DH
EPEBIFIEA'I'IDH
Specification
DESCRIPTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine
damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the
V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is
applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the
knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing.
This sequential control can improve engine power, torque and fuel economy.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3874
EEHEHATIG MAE-RAH
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EDRFEE-I-I-fl.
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
HFEF'IEHE
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 3879
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 3880
PHOTD.35
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DESCRIPTION Elm
Description
DESCRIPTION
Manifold Absolute Pressure Sensor (MAPS) is speed-density type sensor and is installed on the
surge tank. This MAPS senses absolute pressure in surge tank and transfers this analog signal
proportional to the pressure to the PCM. The PCM calculates the intake air quantity and engine
speed based on this signal. This MAPS consists of piezo-electric element and hybrid IC that
amplifies the element output signal. The element is silicon diaphragm type and adapts pressure
sensitive variable resistor effect of semi-conductor 100% vacuum and the manifold pressure
applies to both sides of it respectively. That is, this sensor outputs the silicon variation proportional
to pressure change by voltage.
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Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 3882
DESCRIPTION Elm
SPECIFICATION
Description
DESCRIPTION
Manifold Absolute Pressure Sensor (MAPS) is speed-density type sensor and is installed on the
surge tank. This MAPS senses absolute pressure in surge tank and transfers this analog signal
proportional to the pressure to the PCM. The PCM calculates the intake air quantity and engine
speed based on this signal. This MAPS consists of piezo-electric element and hybrid IC that
amplifies the element output signal. The element is silicon diaphragm type and adapts pressure
sensitive variable resistor effect of semi-conductor 100% vacuum and the manifold pressure
applies to both sides of it respectively. That is, this sensor outputs the silicon variation proportional
to pressure change by voltage.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 3883
SEHEIIATIG DIAGRAM
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Customer Interest for Oil Temperature Sensor For ECM: > 09-EM-005 > Jul > 09 > Engine Controls - Oil
Temperature Sensor Oil Leaks
Oil Temperature Sensor For ECM: Customer Interest Engine Controls - Oil Temperature Sensor Oil
Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Oil Temperature Sensor For ECM: > 09-EM-005 > Jul > 09 > Engine
Controls - Oil Temperature Sensor Oil Leaks
Oil Temperature Sensor For ECM: All Technical Service Bulletins Engine Controls - Oil
Temperature Sensor Oil Leaks
Number 09-EM-005
This Technical Service Bulletin supersedes 08-EM-003 to revise the Warranty Information section.
DESCRIPTION:
If a vehicle equipped with a 3.3L engine exhibits an oil leak at the oil temperature sensor, follow the
repair procedure outlined in this bulletin.
APPLICABLE VEHICLES: Models: Santa Fe and Sonata models equipped with the 3.3L V6 engine
INSPECTION PROCEDURE:
Verify the oil leak is from the oil temperature sensor threaded area. Use of florescent dye or baby
powder can be used to isolate the source of the leak.
SERVICE PROCEDURE:
IMPORTANT:
2. Clean off any loose residue from the sealing threads of the oil temperature sensor.
3. Wipe clean the oil port and surrounding areas of the cylinder head.
4. Apply a small amount of Permatex(R) High Temperature Thread Sealant (#56521) or equivalent
to the oil temperature sensor threads.
NOTE:
Follow the appropriate application directions of the sealant product to allow sufficient curing time
before reassembly.
WARRANTY INFORMATION
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 3899
HI'EFIEHD
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 3901
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 3902
SPEEIFIGATDH
Oil Temperature Sensor For ECM: Description and Operation
DESCRIPTION
Continuously Variable Valve Timing (CVVT) system controls valve overlap by forcibly activating the
camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas (NOx,
HC) and improves fuel economy, idle state, torque in low speed and power in high speed. This
system uses engine oil pressure and consists of the two CVVT Oil Control Valves (OCV) in each
bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
Specification
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 3903
SCHEIIA'I'IG DIAGRAH
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 3904
SPEEIFIGATDH
Oil Temperature Sensor For ECM: Testing and Inspection
DESCRIPTION
Continuously Variable Valve Timing (CVVT) system controls valve overlap by forcibly activating the
camshaft and adjusts EGR (Exhaust Gas Recirculation) amount. It decreases exhaust gas (NOx,
HC) and improves fuel economy, idle state, torque in low speed and power in high speed. This
system uses engine oil pressure and consists of the two CVVT Oil Control Valves (OCV) in each
bank which supplies oil to cam phaser according to PWM (Pulse With Modulator) signal of the
PCM, a CVVT Oil Temperature Sensor (OTS) which detects the oil temperature and a cam phaser
which is installed on the end of the camshaft and converts camshaft phase. The oil getting out of
the CVVT oil control valve flows into the cam phaser and rotates the rotor inside cam phaser. At
this time, the camshaft rotates with the rotor and the cam phase is changed.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Technical
Service Bulletins > Page 3905
SCHEIIA'I'IG DIAGRAH
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine Controls - DTC P0300-P0306 Diagnostics
Oxygen Sensor: Technical Service Bulletins Engine Controls - DTC P0300-P0306 Diagnostics
P0300-P0306 AND/OR FRONT OXYGEN SENSOR DTC
DESCRIPTION:
This bulletin provides diagnostic procedures for 2006- 2007 vehicles with 3.3L3.8L engines and the
following DTC stored: P0300-P0306 engine misfire DTC and Freeze Frame Data Fuel Trim of at
least - 20% indicating rich shift. or any of the following 02 sensor DTC: ^
NOTE:
The vehicle may also exhibit an intermittent hesitation when the engine is at operating temperature.
SERVICE PROCEDURE:
1. DTC P0300-P0306 Misfire but no O2 sensor DTC stored: Inspect the Freeze Frame Data for
either the Long Term or Short Term Fuel Trim shifted -20% or more at a particular bank. The
following example illustrates the fuel trim of -20% or more occurred at Bank-i only:
3. Should either #1 or #2 condition be present replace the related Front O2 sensor at the applicable
bank:
NOTE:
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PM 39210-
PARTS INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine Controls - DTC P0300-P0306 Diagnostics > Page 3912
Bank-2 LH {U P} Sensor.
m arm will! lil'TllE m m
”I “ I I I Bill
Number 10-FL-012
Model 3.3L SANTA FE AND SONATA, 3.8L ENTOURAGE, AZERA, AND VERACRUZ
This bulletin supersedes TSB# 08-FL-002-1 to correct model year and OP Code time.
DESCRIPTION:
This bulletin provides diagnostic procedures for 2006-2009 vehicles with 3.3L/3.8L engines and the
following DTC stored:
P0300-P0306 engine misfire DTC and Freeze Frame Data Fuel Trim of at least - 20% indicating
rich shift.
APPLICABLE VEHICLES: ^ 2006-2009 3.3L Santa Fe and Sonata ^ 2006-2009 3.8L Entourage,
Azera, and Veracruz
SERVICE PROCEDURE:
Inspect the Freeze Frame Data for either the Long Term or Short Term Fuel Trim shifted -20% or
more at a particular bank. The following example illustrates the fuel trim of -20% or more occurred
at Bank-1 only:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine Controls - DTC P0300-P0306 Diagnostics > Page 3914
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2. Inspect for any of the following Front 02 sensor DTC(s) stored:
NOTE:
The following Rear 02 sensor DTC may have set as a result of the Front 02 sensor:
PARTS IHFDRHATIDN:
PARTS INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine Controls - DTC P0300-P0306 Diagnostics > Page 3916
TIME PIN
BEHEDEAEEY-DIYGEH aflluamm
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BEHEDEAEEY—DIYGEH 3921!]3Elfll]
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BENEDE ASST-DIYGEH Bfllflfifllflfl
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W 3921u3u1uu
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Page 3917
Bank 1 / Sensor 2
Bank 2 / Sensor 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3920
Bank 2 / Sensor 2
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3921
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 3922
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sznsanlauszi !
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions
THEE: -
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3926
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3929
E .
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3930
35
3
Symbols Part 1
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3931
.—
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Symbols Part 2
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3932
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3934
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3935
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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and Instructions > Page 3936
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3938
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3939
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3940
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3941
DESCRIPTION
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream
and downstream of the Manifold Catalyst Converter (MCC). After it compares oxygen consistency
of the atmosphere with the exhaust gas, it transfers the oxygen consistency of the exhaust gas to
the PCM. When A/F ratio is rich or lean, it generates approximately 1 V or 0 V respectively. In order
that this sensor normally operates, the temperature of the sensor tip is higher than 370 degrees C
(698 degrees F). So it has a heater which is controlled by the PCM duty signal. When the exhaust
gas temperature is lower than the specified value, the heater warms the sensor tip.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3942
0:5 -1..uov
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Oxygen Sensor: Testing and Inspection
DESCRIPTION
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream
and downstream of the Manifold Catalyst Converter (MCC). After it compares oxygen consistency
of the atmosphere with the exhaust gas, it transfers the oxygen consistency of the exhaust gas to
the PCM. When A/F ratio is rich or lean, it generates approximately 1 V or 0 V respectively. In order
that this sensor normally operates, the temperature of the sensor tip is higher than 370 degrees C
(698 degrees F). So it has a heater which is controlled by the PCM duty signal. When the exhaust
gas temperature is lower than the specified value, the heater warms the sensor tip.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3943
WAVEFDR“
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Waveform
Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Detail
'-
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations >
Page 3947
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Overview
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations >
Page 3948
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2135/P0638
Group: FUEL SYSTEM
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 3957
Frant
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Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 3958
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NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 3964
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 3965
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 3966
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4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 3967
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6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 3968
ECU Upgrade
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update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest for Throttle Position Sensor: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's
P2135/P0638 > Page 3969
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
EAlEAL
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Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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ON/DTC's P2135/P0638 > Page 3977
Frant
Back
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Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
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ON/DTC's P2135/P0638 > Page 3978
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NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
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ON/DTC's P2135/P0638 > Page 3984
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
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ON/DTC's P2135/P0638 > Page 3985
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
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ON/DTC's P2135/P0638 > Page 3986
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4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
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ON/DTC's P2135/P0638 > Page 3987
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6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
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ON/DTC's P2135/P0638 > Page 3988
ECU Upgrade
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update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
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ON/DTC's P2135/P0638 > Page 3989
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
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CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
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Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Information and Instructions > Page 3996
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Information and Instructions > Page 3999
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Information and Instructions > Page 4000
35
3
Symbols Part 1
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Information and Instructions > Page 4001
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Symbols Part 2
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Information and Instructions > Page 4002
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4008
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4009
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4010
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No
Start In P/N
Group TRANSAXLE
Number 09-AT-013
This TSB supersedes TSB 03-40-013 to add repair information (Steps 2-3).
DESCRIPTION:
An improperly adjusted or improperly operating range switch may result in the following conditions:
This TSB provides information concerning the proper adjustment and diagnosis of the transaxle
range switch.
PARTS INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No
Start In P/N > Page 4019
MODEL OPERA“ MATURE
TIME CODE cane
IDDFDB Elantm Sudan
1BBE~D5 Sunni-a
Ill
2m3~ lumn
“5
2m1~ [15 JILGEDD
EDDE~ Accent
2306*- Mara 4270mm C15
BEEF- Elantra Sedan
2DDE~ Elantra Taming
[LB
EDDF Entuuragu
2m1~ Santa Fa
20W- Sunata
EDGE- Tumn
All EDS
m m I13
umfinn
a t pillar
EMF
WARRANTY INFORMATION
Service Procedure
1. Attach a GDS and check for DTC in both the "Engine" and "Automatic Transaxle" menus. Go to
Step 2 for 2000-02 Accent or Step 3 for 2006-Sonata. For other vehicles, go to Step 4.
a. Check the rear combination lamp ground bolts for tightness and good electrical contact (refer to
applicable ETM, "Tail, Parking & License Lamps" section). Go to Step b.
b. For 2006-Sonata: Remove the center console cover and check for contamination on the M40
connector to the sports mode switch. If so, clean and repair the connector as necessary. Go to step
c below.
c. For 2006-07 Sonata: Remove the front pillar cover and verify the harness is properly routed near
the clip. Repair the harness as necessary. Go to Step 4.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No
Start In P/N > Page 4020
SHIFI' LEVER 603
P PIN
R R
N PIN
D D
4. Attach a GDS and select vehicle, "A/T" menu, "Current Data" and "Shift Lever Switch".
5. Move the shift lever and confirm the GDS reads the gear shift position as shown above. If so, the
harness currently does not have an open or short circuit between. the PCM/TCM and range switch.
7. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If so, go to Step 8
^ If not, go to Step 11
8. Inspect the connector to the range switch for a bent pin or pin not fully inserted and related
wiring for an open or short circuit. If OK, follow the repair procedure below:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 09-AT-013 > Jul > 09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No
Start In P/N > Page 4021
Insert M5 um: I
10. Attach the lever and nut. Tighten the nut to specification. Go to Step 11.
13. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification. Remove the 5mm drill or M5 bolt.
14. Move the shift lever to the "N" position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
16. Drive the vehicle two key-on to key-off drive cycles, including shifting to gears D, 3, 2, L (if
equipped) and R. If the:
^ DTC resets, repair or replace the control harness. If the DTC sets again, replace the TCM.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode'
Transmission Position Switch/Sensor: Customer Interest A/T - Won't Shift In 'D', Shifts in 'Sports
Mode'
Group: TRANSAXLE
Number: 06-40-013
Model: 2001 ~ SANTA FE & XG, 2002 ~ SONATA, 2003 ~ TIBURON, 2005 ~ TUCSON, 2006 ~
AZERA
DESCRIPTION:
If you are servicing a vehicle equipped with a "SHIFTRONIC(TM)" automatic transaxle that has the
following symptoms, refer to the repair procedure shown below:
^ Will not shift in "D" position, but shifts correctly in "Sports Mode"
TEST PROCEDURE:
A 2 I [I LEVEL, FiLI.
11H :TIHTEI-l
u'f WITH-l
'l' Ulfll' 311 "III
--n|'-;r_ m u m
”HI-1"? ”11!l III" 31-F—
..| j' Ih|:i| 1rlliu'H "Ll
Sports Mada
Select Switch
- "an SUITE“
'I ::.I.||III-.Il
-I Lr'l‘I-f 'El-III'IEII
- . " . E EHI‘IEH
-. HI-lF |I '-
With ignition key "ON" and engine off, select "Sports Mode Select Switch."
Check the operation of the select switch when the shift lever is moved from "D" to "Sports Mode"
and back.
Select:
^ F2, "SCRN" two times (this will isolate top two data to provide a quick refresh rate)
Shift the Sports Mode lever to the upshift and downshift positions and check the operation of the
switches:
SWITCH BOX REPLACEMENT (2001~SANTA FE & XG, 2002 SONATA & 2003 TIBURON):
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' >
Page 4028
If the switches do not operate as shown above, proceed as follows:
1. Refer to the appropriate shop manual, "Body" section and remove the center console.
2. Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
3. Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and
replace the switch box assembly.
GEAR SHIFT LEVER REPLACEMENT (2006 SONATA & AZERA, 2007 SANTA FE):
^ Refer to the appropriate shop manual, 'Body" section, to remove the center console.
^ Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
^ Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and replace
the gear shift lever assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 06-40-013 > Sep > 06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' >
Page 4029
PART NAME
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PARTS INFORMATION:
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE'
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
^ If no DIG are found, go to Step 2.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
m
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4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
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8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' >
Page 4036
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^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 05-40-016 > Oct > 05 > A/T - No Movement in 'DRIVE' or 'REVERSE' >
Page 4037
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
Group TRANSAXLE
Number 09-AT-013
This TSB supersedes TSB 03-40-013 to add repair information (Steps 2-3).
DESCRIPTION:
An improperly adjusted or improperly operating range switch may result in the following conditions:
This TSB provides information concerning the proper adjustment and diagnosis of the transaxle
range switch.
PARTS INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul >
09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 4043
MODEL OPERA“ MATURE
TIME CODE cane
IDDFDB Elantm Sudan
1BBE~D5 Sunni-a
Ill
2m3~ lumn
“5
2m1~ [15 JILGEDD
EDDE~ Accent
2306*- Mara 4270mm C15
BEEF- Elantra Sedan
2DDE~ Elantra Taming
[LB
EDDF Entuuragu
2m1~ Santa Fa
20W- Sunata
EDGE- Tumn
All EDS
m m I13
umfinn
a t pillar
EMF
WARRANTY INFORMATION
Service Procedure
1. Attach a GDS and check for DTC in both the "Engine" and "Automatic Transaxle" menus. Go to
Step 2 for 2000-02 Accent or Step 3 for 2006-Sonata. For other vehicles, go to Step 4.
a. Check the rear combination lamp ground bolts for tightness and good electrical contact (refer to
applicable ETM, "Tail, Parking & License Lamps" section). Go to Step b.
b. For 2006-Sonata: Remove the center console cover and check for contamination on the M40
connector to the sports mode switch. If so, clean and repair the connector as necessary. Go to step
c below.
c. For 2006-07 Sonata: Remove the front pillar cover and verify the harness is properly routed near
the clip. Repair the harness as necessary. Go to Step 4.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul >
09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 4044
SHIFI' LEVER 603
P PIN
R R
N PIN
D D
4. Attach a GDS and select vehicle, "A/T" menu, "Current Data" and "Shift Lever Switch".
5. Move the shift lever and confirm the GDS reads the gear shift position as shown above. If so, the
harness currently does not have an open or short circuit between. the PCM/TCM and range switch.
7. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If so, go to Step 8
^ If not, go to Step 11
8. Inspect the connector to the range switch for a bent pin or pin not fully inserted and related
wiring for an open or short circuit. If OK, follow the repair procedure below:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 09-AT-013 > Jul >
09 > A/T - MIL ON/DTC's P0705/P0707/P0708/No Start In P/N > Page 4045
Insert M5 um: I
10. Attach the lever and nut. Tighten the nut to specification. Go to Step 11.
13. Insert a 5mm drill or M5 (5mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification. Remove the 5mm drill or M5 bolt.
14. Move the shift lever to the "N" position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
16. Drive the vehicle two key-on to key-off drive cycles, including shifting to gears D, 3, 2, L (if
equipped) and R. If the:
^ DTC resets, repair or replace the control harness. If the DTC sets again, replace the TCM.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1720307-02 >
Mar > 07 > A/T Controls - Neutral Position Switch Adaptive Relearn
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Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - Neutral
Position Switch Adaptive Relearn
Resetting Adaptive Learning and Range Switch Neutral Position Learning
If the transaxle or transaxle control unit is replaced, the TCU adaptive learning values must be
reset (erased) and the range switch neutral position must be relearned using either the GDS or
Hi-Scan Pro. If the following procedures are not completed, the following conditions may occur:
^ Stop the vehicle, move the shift lever to "P" and set the parking brake.
Follow the instructions on the screen and confirm the test indicates "Completed:"
Luci-5.9m nut
^ Stop the vehicle, move the shift lever to "N" and set the parking brake.
^ Loosen the nut on the shift cable. Align the dot (o) on the shift lever to the "N" mark on the TCU.
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^ Follow the instructions on the screen and confirm the test indicates "Completed."
^ Move the shift lever from "P" to "D" and confirm the shift position indicator on the dash reads
correctly. Confirm the correct gear indication using the Hi-Scan or GDS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep >
06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode'
Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - Won't Shift In 'D', Shifts
in 'Sports Mode'
Group: TRANSAXLE
Number: 06-40-013
Model: 2001 ~ SANTA FE & XG, 2002 ~ SONATA, 2003 ~ TIBURON, 2005 ~ TUCSON, 2006 ~
AZERA
DESCRIPTION:
If you are servicing a vehicle equipped with a "SHIFTRONIC(TM)" automatic transaxle that has the
following symptoms, refer to the repair procedure shown below:
^ Will not shift in "D" position, but shifts correctly in "Sports Mode"
TEST PROCEDURE:
A 2 I [I LEVEL, FiLI.
11H :TIHTEI-l
u'f WITH-l
'l' Ulfll' 311 "III
--n|'-;r_ m u m
”HI-1"? ”11!l III" 31-F—
..| j' Ih|:i| 1rlliu'H "Ll
Sports Mada
Select Switch
- "an SUITE“
'I ::.I.||III-.Il
-I Lr'l‘I-f 'El-III'IEII
- . " . E EHI‘IEH
-. HI-lF |I '-
With ignition key "ON" and engine off, select "Sports Mode Select Switch."
Check the operation of the select switch when the shift lever is moved from "D" to "Sports Mode"
and back.
Select:
^ F2, "SCRN" two times (this will isolate top two data to provide a quick refresh rate)
Shift the Sports Mode lever to the upshift and downshift positions and check the operation of the
switches:
SWITCH BOX REPLACEMENT (2001~SANTA FE & XG, 2002 SONATA & 2003 TIBURON):
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep >
06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' > Page 4058
If the switches do not operate as shown above, proceed as follows:
1. Refer to the appropriate shop manual, "Body" section and remove the center console.
2. Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
3. Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and
replace the switch box assembly.
GEAR SHIFT LEVER REPLACEMENT (2006 SONATA & AZERA, 2007 SANTA FE):
^ Refer to the appropriate shop manual, 'Body" section, to remove the center console.
^ Check the wiring visually for an open or short circuit. Check related connectors for pins that are
bent or not fully inserted. If ok, go to step 3.
^ Refer to the appropriate shop manual, "Automatic Transaxle Control System" section and replace
the gear shift lever assembly.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 06-40-013 > Sep >
06 > A/T - Won't Shift In 'D', Shifts in 'Sports Mode' > Page 4059
PART NAME
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PARTS INFORMATION:
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 >
Nov > 05 > A/T - No Movement In Drive/Reverse
MODEL: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DTC in both the "Engine" and "Automatic Transaxle" menus:
^ If DTC are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to Step 9
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 >
Nov > 05 > A/T - No Movement In Drive/Reverse > Page 4064
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
shift cable to the lever and install the nut. Tighten the nut to specification.
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^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 >
Nov > 05 > A/T - No Movement In Drive/Reverse > Page 4066
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
12. Install the A/T Tester, P/N 09450-AT000, to the vehicle:
^ Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottompan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an
^ If no problem is found swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse
WARRANTY INFORMATION:
Group: TRANSAXLE
Number: 05-40-016
Model: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear, follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DIG in both the "Engine" and "Automatic Transaxle" menus:
^ If DIG are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
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4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to step 9
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
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8. Move the shift lever to the N position. Attach the shift cable to the lever and install the nut.
Tighten the nut to specification.
Specification: 9-10 ft.lb (12-13 Nm, 120-130 kg.cm)
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-40-016 > Oct >
05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 4073
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^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
11. Move the shift lever to Drive.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted. Check the wiring harness for an open or short circuit. If ok, replace the range switch.
Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottom-pan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves, check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an open or short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 05-40-016 > Oct >
05 > A/T - No Movement in 'DRIVE' or 'REVERSE' > Page 4074
^ If no problem is found, swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse, replace the TCM.
WARRANTY INFORMATION:
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Transmission Position Switch/Sensor: All Technical Service Bulletins A/T Controls - Neutral
Position Switch Adaptive Relearn
Resetting Adaptive Learning and Range Switch Neutral Position Learning
If the transaxle or transaxle control unit is replaced, the TCU adaptive learning values must be
reset (erased) and the range switch neutral position must be relearned using either the GDS or
Hi-Scan Pro. If the following procedures are not completed, the following conditions may occur:
^ Stop the vehicle, move the shift lever to "P" and set the parking brake.
Follow the instructions on the screen and confirm the test indicates "Completed:"
Luci-5.9m nut
^ Stop the vehicle, move the shift lever to "N" and set the parking brake.
^ Loosen the nut on the shift cable. Align the dot (o) on the shift lever to the "N" mark on the TCU.
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^ Follow the instructions on the screen and confirm the test indicates "Completed."
^ Move the shift lever from "P" to "D" and confirm the shift position indicator on the dash reads
correctly. Confirm the correct gear indication using the Hi-Scan or GDS.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov >
05 > A/T - No Movement In Drive/Reverse
MODEL: ALL
DESCRIPTION:
If you are servicing a vehicle with no movement in drive or reverse gear follow the procedure
shown below:
REPAIR PROCEDURE:
1. Check for DTC in both the "Engine" and "Automatic Transaxle" menus:
^ If DTC are found, refer to TSB 05-40-008 or 04-40-020 for repair guidance.
2. Remove the dipstick and check the ATF for a strong burnt smell. If the smell does not provide
conclusive results, remove the oil pan and check for metal particles in the pan:
^ If a strong burnt smell or metal particles are found, replace the transaxle
^ If not, go to Step 3
NOTE:
ATF that is a dark brown or black color does not indicate an internal transaxle concern; do not
replace the transaxle. SPIII may change color to a dark brown after 10,000 to 25,000 miles in
service. This change is normal for this type of ATF.
4. Insert a 5 mm drill or MS (5 mm) bolt in the adjustment hole of the range switch. Check that the
drill or bolt fits into the adjustment holes.
^ If not, go to Step 5
^ If so, go to Step 9
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov >
05 > A/T - No Movement In Drive/Reverse > Page 4086
7. Insert a 5 mm drill or M5 (5 mm) bolt in the adjustment hole of the range switch. Tighten the two
10 mm mounting bolts to specification.
shift cable to the lever and install the nut. Tighten the nut to specification.
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“‘-
‘ "I'-
- ' fi .
__"-'I
"-1-.
H
l I!
Wu: I l m m l l m l l m l l m l l m fl
^ Vehicle
^ If "R" is displayed, the TCM is receiving the correct signal from the range switch. Go to Step 11.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
^ If "D" and "GEAR 1" are displayed, the TCM is receiving the correct signal from the range switch.
Go to Step 12.
^ If not, check the connector at the TCM and the range switch for a bent pin or pin not fully
inserted.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > tnt1581105-02 > Nov >
05 > A/T - No Movement In Drive/Reverse > Page 4088
Check the wiring harness for an open or short circuit. If ok, replace the range switch.
12. Install the A/T Tester, P/N 09450-AT000, to the vehicle:
^ Shift the transaxle to "D". Move the gear selector switch of the A/T Tester and shift manually in 1,
2, 3, 4, and 5 gears (if equipped).
NOTE:
Use the "EF, XG" switch for side-pan transaxles and the "LC" switch for bottompan transaxles.
^ Disconnect the A/T Tester from the solenoid. Do not reconnect the harness connector to the
solenoid. Shift the transaxle to "R".
^ If the vehicle moves check the harness connector at the TCM and the solenoid for a bent pin or
pin not fully inserted. Check the wiring harness for an
^ If no problem is found swap a TCM from a similar vehicle and test for movement in Drive and
Reverse. If the vehicle moves in Drive and Reverse
WARRANTY INFORMATION:
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Component
Locations > Page 4093
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4096
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4099
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4100
35
3
Symbols Part 1
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4101
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4102
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4104
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4105
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4106
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4107
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4108
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Information and Instructions > Page 4109
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4111
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Connector Views: The Connector Pin Out Views for connectors shown on these diagrams can be
found on the Connector Pin Out images that follow most sets of system diagrams.
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1. Connect the positive (+) lead from battery to terminal 1 and negative (-) lead to terminal 2. 2.
Connect the positive (+) lead from tester to terminal 3 and the negative (-) lead to terminal 2. 3.
Rotate the shaft. 4. Check that there is voltage change from approx. 0 V to 11 V or more between
terminals 3 and 2.
5. The voltage change should be 4 times for every revolution of the speed sensor shaft.
REPLACEMENT
1. Disconnect the vehicle speed sensor connector (B). 2. Remove the bolt (10 mm [0.4 inch]). 3.
Inspect the vehicle speed sensor bore.
3. Inspect the O-ring for nicks or cut. Install a new O-ring as necessary. 4. Apply a light coat of
automatic transaxle fluid to the O-ring seal before installation. 5. Install the vehicle speed sensor. 6.
Connect the vehicle speed sensor connector. 7. Installation is the reverse of removal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor: > 10-EE-002 > Jul > 10 > Engine Controls -
MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor: > 07-36-006 > Sep > 07 > Engine Controls -
Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - Low Power/MIL ON/DTC
P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
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Example GDS DTC screen shown.
DP CASUAL CUBE
firljflDEL 01’ NAME TIME PART I
NATURE CAUSE
327m 3mm
msmnw DIAGHDEIE
3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Accelerator Pedal Position Sensor: > 10-EE-002 > Jul > 10 > Engine
Controls - MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Accelerator Pedal Position Sensor: > 07-36-006 > Sep > 07 > Engine
Controls - Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - Low
Power/MIL ON/DTC P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
j
a Frau“ Frlma j
m m m m m : m u
l m h | II'h'lTl-fl
Human—um cum -
n nun-1mm I.- I
‘ thumb: luflnhflnflmnflihm II 'f
:ITSEI Sill-ITE- nan-mun I.- I
Llfll 'l— Fufl 'l'I-I-llfli 4.! fl
III-I 'I‘Il-Fufl'I'h-ld!‘ u I
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HEU EEEE null -nan : W
Example GDS DTC screen shown.
DP CASUAL CUBE
firljflDEL 01’ NAME TIME PART I
NATURE CAUSE
327m 3mm
msmnw DIAGHDEIE
3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 4145
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 4147
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Overview
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 4148
No.53
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 4149
DEECRIPTIDH emu:
Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 4150
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Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical
Service Bulletins > Page 4151
SCHEHATIE DMHAH
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Schematic Diagram
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications
Detail
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 4156
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 4157
1' . --.
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4160
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4163
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4164
35
3
Symbols Part 1
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4165
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Symbols Part 2
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4166
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4168
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Information and Instructions > Page 4171
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Information and Instructions > Page 4172
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Information and Instructions > Page 4173
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
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SPECIFICATION
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Air Flow Meter/Sensor: Testing and Inspection
DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
Specification
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638
Throttle Position Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2135/P0638
Group: FUEL SYSTEM
Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4186
From:
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4187
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4191
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NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4193
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4194
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4195
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4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4196
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6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4197
ECU Upgrade
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8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
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Bulletins > Customer Interest: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page 4198
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
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Number: 10-FL-010
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability
list. It also provides instructions to select the most recent available ECM Update Events #166-178
or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or
more of the following conditions:
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp
home" mode and stored the following DTC in the ECM:
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
REPAIR ACTION:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to
ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update
event data at time of your update.
NOTE:
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4206
Frant
Back
Laafspflng
Eidl
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process.
It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect
ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON
IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below
ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB
publication however, you may select a later event number if one is shown in the ECM update list
even if it describes another issue. This would generate a more recent ROM ID than shown below
but it also includes the update from this TSB.
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Bulletins > All Technical Service Bulletins: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page
4207
mm ID
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NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update
than K-Line.
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Bulletins > All Technical Service Bulletins: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page
4213
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove
ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new
TPS.
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4214
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the
engine to ensure an adequate battery charge state for reliable update results. The ECM Update
procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to
occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not
work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge
(half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge
is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including
heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the
update.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will
inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version
followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
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4215
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4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page
double click at GDS at top left of the screen to go back to
home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the
vehicle's ECM, then select Engine Control as system
and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available
updates for the vehicle. Select the latest available
(highest number) update event even if it describes another issue. After clicking the Upgrade button
then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued.
However be sure to select the highest number event available in the list even if it describes another
issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this
TSB.
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4216
I«'Iehuirflle 51W Management
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IF TD” WT,
THE SYSTEM DUES MDT WORK.
6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for
update based on the event that you select. Choose
the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at
least 12 volts required to ensure reliable update results.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to
ensure an adequate battery charge state for reliable
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Bulletins > All Technical Service Bulletins: > 10-FL-010 > Aug > 10 > Engine Controls - MIL ON/DTC's P2135/P0638 > Page
4217
ECU Upgrade
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update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer
key teaching procedure on the affected vehicles
where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a
result of temporary loss of CAN communication during
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after
the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then
reconnecting them before trying the Manual Mode ECM Update.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate
event number from the table provided in Auto
mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table
and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table
to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the
correct system and password.
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4218
CM SPHTA FE 2313.3 ECM UPDATE - H LINE
MENU m
OM 3-1 9M1 NON IMMO: 39199-39319 3319
CM 3.1 AT NON IMMO: 39199-3E9391339 3339
CM 3.3 NON IMMO: 39119-39999 3999
GM 33 NON IMMO: 39119-39991 3991
DM SANTAFE 3.1 EOM UPDATE - DAN
MENU m
OM 2.1 9119 NON IMMO: 39199-39312199M11 3313
CM 3.1 9119 NON IMMO: 39199-3931419911119 331—4
OM 3.1.41 NON IMMO: 39199-3E9321933 {DEMYJ 3933
CM 3.1 AT NON IMMO: 39199-3E934199M11 3934
OM SANTAPE 3.3 EOM UPDATE - OAN
MENU PASSWORD
GM 33 NON IMMO: 39119-39992 {DfiMY} 399—2
OM 3.3 NON IMMO: 39119-399931:m 3993
OM 3.3 NON IMMO; 39119-399941m 3994
CM 3.3 NON IMMO: 3911939999199M11 3999—
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be
displayed. Turn the ignition key OFF for 10
seconds, place it back in the ON position and then select OK.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and
clear the DTC (5) present.
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q
Wiring Harness: All Technical Service Bulletins Electrical - A/T DTC P0708/Electrical Faults
Group: TRANSAXLE
Number: 06-40-015
_
:
Date: OCTOBER, 2006
DESCRIPTION:
If a 2006-07 Sonata has the following symptoms, follow the Repair Procedure shown below.
^ Vehicle will not move in Drive, shift lever indicator light displays "R" and backup lights are on
when the shift lever is in Drive.
^ Dome light, map light, sunroof, vanity lamps and trunk light inoperative (see 2006-07 Sonata
ETM, page SD929-2)
^ Accessories (A/C blower, sunroof, dome light, security alarm and wipers) operate with the ignition
key removed from the ignition switch.
REPAIR PROCEDURE
1. Remove the cap from the front pillar cover, remove the screw and remove the front pillar cover.
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P0708/Electrical Faults > Page 4226
2. Check the harness for a short to ground near the clip. Repair the harness as necessary and
wrap the wires with electrical tape.
3. Reinstall the front pillar cover.
WARRANTY INFORMATION:
WARRANTY INFORMATION:
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Information and Instructions
THEE: -
$;:-.
. - I - ...|._......L._... .
..I—I....i-rpr. .
p ..
H...H.H1..H....
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Information and Instructions > Page 4237
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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M m m m h m m m m m bnl
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Information and Instructions > Page 4240
E .
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Information and Instructions > Page 4241
35
3
Symbols Part 1
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Information and Instructions > Page 4242
.—
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.r
.-
n
r
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h
l
n
.—
I
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H
J
i.
l
I
I
Symbols Part 2
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Information and Instructions > Page 4243
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Information and Instructions > Page 4245
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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murmur wuss M
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EEHFEIIIA
Camshaft Position Sensor: Component Locations
Bank 1
Bank 2
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Page 4258
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Overview
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Page 4259
PHOTO.35
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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35
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Symbols Part 1
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Symbols Part 2
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The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4277
DESCRIPTION Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft
position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects
the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which out- put voltage changes when magnetic field is made on the IC with
current flow. So the sequential injection of the 6 cylinders is impossible without CMPS signal.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4278
DESCRIPTION Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft
position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects
the piston position of each cylinder which the CKPS can't detect. The two CMPS are installed on
engine head cover of bank 1 and 2 and uses a target wheel installed on the camshaft. This sensor
has a hall-effect IC which out- put voltage changes when magnetic field is made on the IC with
current flow. So the sequential injection of the 6 cylinders is impossible without CMPS signal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4279
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4283
Detail
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4286
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Instructions > Page 4289
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4290
35
3
Symbols Part 1
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4291
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4292
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Instructions > Page 4294
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Instructions > Page 4295
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Instructions > Page 4297
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4298
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Instructions > Page 4299
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Instructions > Page 4300
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4301
DESCRIPTION Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of
the most important sensors of the engine control system. If there is no CKPS signal input, fuel is
not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal.
This sensor is installed on transaxle housing and generates alternating current by magnetic flux
field which is made by the sensor and the target wheel when engine runs. The magnetic flux
increases when the protrusion of the target wheel is getting near to the sensor and does not
change in the most close position. When the protrusion becomes estranged from the sensor,
magnetic flux disappears and alternating current is generated. The target wheel consists of 58 slots
and 2 missing slots on 360 CA (Crank Angle).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4302
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DESCRIPTION Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of
the most important sensors of the engine control system. If there is no CKPS signal input, fuel is
not supplied and the main relay does not operate. That is, vehicle can't run without CKPS signal.
This sensor is installed on transaxle housing and generates alternating current by magnetic flux
field which is made by the sensor and the target wheel when engine runs. The magnetic flux
increases when the protrusion of the target wheel is getting near to the sensor and does not
change in the most close position. When the protrusion becomes estranged from the sensor,
magnetic flux disappears and alternating current is generated. The target wheel consists of 58 slots
and 2 missing slots on 360 CA (Crank Angle).
Waveform
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4303
EGEEHATIG DIAGRAM
Schematic Diagram
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Locations
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions
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Ignition Switch: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
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Page 4309
and the function of other relevant circuits at once. It is applicable to real service work.
- It is very important to understand relevant circuits exactly before troubleshooting diagnosis.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
wfif?)@:mmmmmmrul2ml
tha color uf 1h: calm uf
backgrmfl‘rd Stripe
M m m m h m m m m m bnl
unmahamnshyuulsfordltaiadsrmhnl 5W"
NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
06 WIRE COLOR ABBREVIATIONS
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
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Page 4312
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Electrical wiring connectors are classified according to the wiring pans in the Harness Layouts.
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
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Page 4313
35
3
Symbols Part 1
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Page 4314
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 4315
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
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Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 4317
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Page 4318
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
2. Continuity Check Method
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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Page 4319
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
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Page 4320
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Page 4321
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
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Page 4322
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
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Page 4323
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 4324
INSPECTION
1. Disconnect the ignition switch connector and key warning switch connector from under the
steering column. 2. Check for continuity between the terminals. 3. If continuity is not specified,
replace the switch.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 4325
Ignition Switch: Service and Repair
REPLACEMENT
3. Remove the ignition switch (A) after loosening the screw and disconnecting the 6P connector. 4.
Remove the steering column shaft.
5. Remove the key warning switch and key illumination lamp (A) after loosening the screws and
disconnecting the 6P connector.
6. If it is necessary to remove the key lock cylinder (A), Remove the key lock cylinder (A) after
pushing lock pin (B) with key ON. 7. Installation is the reverse of removal procedure.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 4330
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Component Locations > Page 4331
PHDTIJ.”
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Knock Sensor: Connector Locations
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4332
SPEC IFEATI-DH
Specification
DESCRIPTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine
damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the
V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is
applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the
knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing.
This sequential control can improve engine power, torque and fuel economy.
Item.......................................................................................................................................................
..............................................................Specification
Capacitance..........................................................................................................................................
..........................................................1,480 - 2,220 pF
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Hyundai Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4333
EPEL' IFEATI-DH
EPEBIFIEA'I'IDH
Specification
DESCRIPTION
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine
damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the
V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is
applied as pressure to the piezoelectric element. At this time, this sensor transfers the voltage
signal higher than the specified value to the PCM and the PCM retards the ignition timing. If the
knocking disappears after retarding the ignition timing, the PCM will advance the ignition timing.
This sequential control can improve engine power, torque and fuel economy.
Specification
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4334
EEHEHATIG MAE-RAH
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Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Standard
Value:.....................................................................................................................................374 -
384 kPa (3.82 - 3.92 kg/sq.cm, 54.3 - 55.8 psi)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications > Page 4339
1. PREPARING
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1. Dleeemeet the fuel teed heee Hunt the dellvenr pipe.
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. Install the Fuel Freeeute Gauge Ampler {MWJretween the dellttery pipe and lhe fuel feed I'Ittee+
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Idle Speed
A/C ON OFF
Natural,N,P-range.................................................................................................................................
.........................................................620 ± 100 rpm D-range...............................................................
.........................................................................................................................................620 ± 100
rpm
A/C ON ON
Natural,N,P-range.................................................................................................................................
.........................................................620 ± 100 rpm D-range...............................................................
...........................................................................................................................................620 ± 100
rpm
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair
1. Disconnect the fuel pump connector(A). 2. Start the engine and wait until fuel in fuel line is
exhausted. 3. After the engine stalls, turn the ignition switch to OFF position and disconnect the
negative (-) terminal from the battery.
NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel feed hose, otherwise fuel
will spill out.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
..............................................................................................................................................................
............................................
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Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
©®®
Frunt uf 1'ul'rmlnllr';
NOTE: when removing the ignition coil connector, pull the lock pin(A) and push the clip(B).
CAUTION: Be careful that no contaminates enter through the spark plug holes.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection > Page 4359
IHEFEEHUH HF R E M
Fuel mhtm
tun rl'fl'l
Lulu drlnlalu: -
4. Inspect the electrodes (A) and ceramic insulator (B).
NGK .....................................................................................................................................................
.................................................................. IFR5G-11
Gap ......................................................................................................................................................
................................ 1.0-1.1 mm (0.039-0.043 inch)
Torque .................................................................................................................................................
............................................. 20-30 Nm (15-22 lb.ft)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 4363
Spark Plug: Application and ID
NGK .....................................................................................................................................................
.................................................................. IFR5G-11
Gap ......................................................................................................................................................
................................ 1.0-1.1 mm (0.039-0.043 inch)
Torque .................................................................................................................................................
............................................. 20-30 Nm (15-22 lb.ft)
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Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 4364
Spark Plug: Testing and Inspection
NOTE: when removing the ignition coil connector, pull the lock pin(A) and push the clip(B).
CAUTION: Be careful that no contaminates enter through the spark plug holes.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 4365
IHEFEEHUH HF R E M
Fuel mhtm
tun rl'fl'l
Lulu drlnlalu: -
4. Inspect the electrodes (A) and ceramic insulator (B).
ENGINE COMPRESSION
Compression pressure
................................................................................................................................................. 1,283
kPa (13.0 kgf/cm2, 185 psi) Minimum pressure
......................................................................................................................................................
1,135 kPa (1 1.5 kgf/cm2, 164 psi) Difference between each cylinder
............................................................................................................................ 100 kPa (1.0
kgf/cm2, 15 psi) or less
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check
> System Information > Specifications > Page 4369
Compression Check: Testing and Inspection
COMPRESSION
NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking
the engine, measure the compression pressure.
NOTE: Always use a fully charged battery to obtain engine speed of 200 rpm or more.
Compression pressure 1,283 kPa (13.0 kgf/cm2, 185 psi) Minimum pressure: 1,135 kPa (1 1.5
kgf/cm2, 164 psi) Difference between each cylinder 100 kPa (1.0 kgf/cm2, 15 psi) or less
e. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into
the cylinder through the spark plug hole and
repeat steps (a) through (c) for cylinders with low compression. ^
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
^ If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
Intake ...................................................................................................................................................
.................. 0.10 - 0.30 mm (0.0039 - 0.0118 inch) Exhaust ...............................................................
................................................................................................... 0.20 - 0.40 mm (0.0079 - 0.0157
inch)
Specification
Intake ...................................................................................................................................................
................. 0.17 - 0.23 mm (0.0067 - 0.0090 inch) Exhaust ................................................................
.................................................................................................. 0.27 - 0.33 mm (0.0106 - 0.0129
inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 4373
Valve Clearance: Adjustments
NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature: 20°C) and cylinder head is installed on the cylinder block.
1. Remove the engine cover. 2. Remove air cleaner assembly. 3. Remove the surge tank.
a. Disconnect the ignition coil connector and remove the ignition coil. b. Disconnect the breather
hose (A) from the cylinder head cover.
c. Loosen the cylinder head cover bolts and then remove the cover (A) and gasket.
a. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain
cover.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 4374
HH Ex HAUET
a. Check only the valve indicated as shown. [No. 1 cylinder: TDC/Compression] measure the valve
clearance.
- Using a thickness gauge, measure the clearance between the tappet and the base circle of
camshaft.
- Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting tappet.
Valve clearance Specification Engine coolant temperature: 20°C [68°F] Limit Intake: 0.10 - 0.30
mm (0.0039 - 0.0118 inch) Exhaust: 0.20 - 0.40 mm (0.0079 - 0.0157 inch)
b. Turn the crankshaft pulley one revolution (360") and align the groove with timing mark T of the
lower timing chain cover.
a. Set the No. 1 cylinder to the TDC/compression. b. Remove the timing chain. c. Remove the
camshaft bearing caps (A).
g. Calculate the thickness of a new tappet so that the valve clearance comes within the specified
value.
h. Select a new tappet with a thickness as close as possible to the calculated value.
NOTE: Shims are available in 41 size increments of 0.015 mm (0.0006 inch) from 3.00 mm (0.118
inch) to 3.600 mm (0.1417 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 4376
i. Place a new tappet on the cylinder head.
NOTE: Apply engine oil at the selected tappet on the periphery and top surface.
m. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft
sprocket and camshaft sprocket timing marks. n. Recheck the valve clearance.
Valve clearance (Engine coolant temperature: 20°C [68°F]) [Specification] Intake: 0.17 - 0.23 mm
(0.0067 - 0.0090 inch) Exhaust: 0.27 - 0.33 mm (0.0106 - 0.0129 inch)
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor:
> 10-EE-002 > Jul > 10 > Engine Controls - MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Customer Interest for Accelerator Pedal Position Sensor:
> 07-36-006 > Sep > 07 > Engine Controls - Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: Customer Interest Engine Controls - Low Power/MIL ON/DTC
P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
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PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal
Position Sensor: > 10-EE-002 > Jul > 10 > Engine Controls - MIL ON/DTC P2138/P2127/P2122/P2106
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC
P2138/P2127/P2122/P2106
Group: ENGINE ELECTRICAL
Number: 10-EE-002
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engines may exhibit MIL illumination with any of
the following DTC stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E > 4.5%)
The vehicle may have run at reduced power in "limp home mode" in the past and also set the
following DTC:
APPLICABILITY:
^ 2006-2007 TG Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM only for the occurrence of DTC P2106 without the
presence of P2138, P2127, or P2122.
SERVICE PROCEDURE:
1. Use the GDS to determine if any of the following DTC have been stored:
fl FI'BFIE Fffll'l'lfll
mmummaaannilnul: i m m—fiam-
PARTS INFORMATION:
NOTE:
For adjustable type pedal, only the pedal will be replaced; not with the bracket and adjuster motor.
WARRANTY INFORMATION:
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal
Position Sensor: > 07-36-006 > Sep > 07 > Engine Controls - Low Power/MIL ON/DTC P2138/P2127/P2122
Accelerator Pedal Position Sensor: All Technical Service Bulletins Engine Controls - Low
Power/MIL ON/DTC P2138/P2127/P2122
Group: ENGINE ELECTRICAL
Number: 07-36-006
DESCRIPTION:
Symptom/Condition:
Some 2006-2007 vehicles with 3.3L/3.8L gasoline engine may exhibit MIL illumination with any of
the following DTC found stored:
^ P2138 - Pedal position sensor D/E correlation (difference between sensor D & E is too much error
greater then 4.5%)
And the vehicle may have run at reduced power in "limp home mode" in the past and set the
following DTC indicating such:
APPLICABILITY:
^ 2006-2007 Azera
REPAIR:
NOTE:
Do not replace ETC throttle body or PCM for the DTC P2106 as it is the result of the pedal sensor
incident!
SERVICE PROCEDURE:
1. Inspect for the stored DTC with GDS and look for the existence of any of the following DTC for
this bulletin to apply:
‘TFI
J '-'II | : | - u - ' - . l r r I r - - ! . - ; + | I I I ' I
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DP CASUAL CUBE
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NATURE CAUSE
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3535mm
50mm gamma-AWE. 327m 033m m1: "cos
INF} msmnw DIAGNOSIS “WE RETHHLWI]
PARTS INFORMATION
WARRANTY INFORMATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Page 4407
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Page 4408
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Page 4409
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Page 4410
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Page 4411
DEECRIPTIDH emu:
Description
DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Page 4412
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DESCRIPTION
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the
rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine
control system, so it consists of the two sensors which adapt individual sensor power and ground
line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the
ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic system judges
that it is abnormal.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Sensor > Component Information > Technical Service Bulletins > Page 4413
SCHEHATIE DMHAH
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Schematic Diagram
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Specifications
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Specifications > Page 4418
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Specifications > Page 4419
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions
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Air Flow Meter/Sensor: Diagram Information and Instructions
Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4422
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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NOTE: UNLESS OTHERWISE STATED, ALL CONNECTOR VIEWS ARE FROM THE TERMINAL
SIDE OF THE CONNECTOR.
The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4425
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4426
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4427
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4428
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4430
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4431
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4432
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4433
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4434
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4435
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4436
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 4437
DESCRIPTION
Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 4438
SPECIFICATION
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Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner
and the throttle body. It consists of a tube, a sensor assembly and honey cell and detects intake air
quantity flowing into the intake manifold. While the intake air coming out of the air cleaner flows by
the honey cell, it becomes laminar flow, and then it passes the hot-film. At this time, heat transfer is
generated by convection and this sensor loses its energy. This sensor detects the mass air flow by
using the energy loss and transfers the information to the PCM by frequency. The PCM calculates
fuel quantity and ignition timing.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Diagrams > Page 4439
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Specifications
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Specifications > Page 4444
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Specifications > Page 4445
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DESCRIPTION Intake Air Temperature Sensor (IATS) is installed inside the Mass Air Flow Sensor
(MAFS) and detects the intake air temperature. To calculate precise air quantity, correction of the
air temperature is needed because air density varies according to the temperature. So the PCM
uses not only MAFS signal but also IATS signal. This sensor has a Negative Temperature
Coefficient (NTC) and its resistance is in inverse proportion to the temperature.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Specifications > Page 4446
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DESCRIPTION Intake Air Temperature Sensor (IATS) is installed inside the Mass Air Flow Sensor
(MAFS) and detects the intake air temperature. To calculate precise air quantity, correction of the
air temperature is needed because air density varies according to the temperature. So the PCM
uses not only MAFS signal but also IATS signal. This sensor has a Negative Temperature
Coefficient (NTC) and its resistance is in inverse proportion to the temperature.
Specification
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature
Sensor > Component Information > Specifications > Page 4447
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Specifications
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Specifications > Page 4451
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions
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Schematic Diagrams
- Each diagram is consisted of circuits by system. This schematic diagram includes the path of
electricity flow, connection condition for each switch,
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4454
and the function of other relevant circuits at once. It is applicable to real service work.
- Circuits by system depends upon part number and are indicated on schematic diagram index.
- The connector figure of consisted parts in the schematic diagram by system is indicated at the
end of schematic diagram.
- It shows the front of the connector on the harness side with not connecting the components to
harness connector. The number of terminal being in use is in accordance with the way obtaining
number and unused terminal is marked with (*).
03 CONNECTOR CONFIGURATIONS (CONNECTION BETWEEN HARNESSES)
- When connecting the harness with connector between harnesses, it shows female and male
connectors and indicates them on the connector configurations group.
04 COMPONENT LOCATIONS
- To find the components easily, component locations diagram is indicated with "PHOTO NO" on
the lower of component name.
- To make it easy to distinguish connectors, the connector in the picture is indicated being installed
in the vehicle.
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The abbreviations are used to identify wire colors in the circuit schematics.
07 HARNESS CLASSIFICATION
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4457
E .
08 CONNECTOR IDENTIFICATION
Example
NOTE: Connectors which connect each wiring harness are represented by the symbols as in below
diagram.
Example
A junction block identification symbol consists of a wiring harness location classification symbol
corresponding to a wiring harness location and number corresponding to the connector in the
junction block.
HARNESS LAYOUTS
Harness layouts show the routing of the major wiring harnesses, the in-line connectors and the
splices between the major harnesses. These layouts will make electrical troubleshooting easier.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4458
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4459
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4460
The measured resistance at high temperature after vehicle running may be high or low. So all
resistance must be measured at ambient temperature (20 degrees C, 68 degrees F), unless there
is any notice.
NOTE: The measured resistance in except for ambient temperature (20 degrees C, 68 degrees F)
is reference value.
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does
not occur again during testing. An example would be if a problem appears only when the vehicle is
cold but has not appeared when warm. In this case, the technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and recreate (simulate) the environment and
condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent,
broken or corroded pins, and then verify that the
3. Slightly shake the connector and wiring harness vertically and horizontally. 4. Repair or replace
the component that has a problem. 5. Verify that the problem has disappeared with the road test.
SIMULATING VIBRATION
:Lightly shake the connector and wiring harness vertically and then horizontally.
SIMULATING HEAT
a. Heat components suspected of causing the malfunction with a hair dryer or other heat source.
WARNING: -
a. Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
WARNING: DO NOT sprinkle water directly into the engine compartment or electronic components.
a. Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, etc.).
1. Handling of Connector
b. When removing the connector with a lock, press or pull locking lever.
c. Listen for a click when locking connectors. This sound indicates that they are securely locked.
d. When a tester is used to check for continuity, or to measure voltage, always insert tester probe
from wire harness side.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4462
e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot
be accessed from harness side.
NOTE: -
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
d. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
a. Clean the contact points using air gun and/or shop rag.
NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may
be damaged.
1. Before removing the wire harness, check the wire harness position and crimping in order to
restore it correctly. 2. Check whether the wire harness is twisted, pulled or loosened. 3. Check
whether the temperature of the wire harness is abnormally high. 4. Check whether the wire harness
is rotating, moving or vibrating against the sharp edge of a part. 5. Check the connection between
the wire harness and any installed part. 6. If the covering of wire harness is damaged:
secure,repair or replace the harness.
- Continuity Check
- Voltage Check
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4463
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity
Check Method) or Step 3 (Voltage Check Method) as shown below.
NOTE: When measuring for resistance, lightly shake the wire harness above and below or from
side to side.
Specification (Resistance) 1 Ohm or less -> Normal Circuit 1 MOhm or Higher-> Open Circuit
a. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as
shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1 MOhm and below 1 Ohm
respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point,
check sub line of line 1 as described in next step.
b. Disconnect connector (B), and measure for resistance between connector (C) and (B1). and
between (B2) and (A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1 MOhm and
the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4464
3. Voltage Check Method
a. With each connector still connected, measure the voltage between the chassis ground and
terminal 1 of each connectors (A), (B) and (C) as
The measured voltage of each connector is 5 V, 5 V and 0 V respectively. So the open circuit is
between connector (C) and (B).
4. Test Method for Short to Ground Circuit Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing
below Step 2 (Continuity Check Method with Chassis Ground) as shown below.
NOTE: Lightly shake the wire harness above and below, or from side to side when measuring the
resistance.
Specification (Resistance) 1 Ohm or less -> Short to Ground Circuit 1 MOhm or Higher -> Normal
Circuit
a. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis
Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ohm and higher than 1 MOhm
respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken
point, check the sub line of line 1 as described in the following step.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4465
b. Disconnect connector (B), and measure the resistance between connector (A) and chassis
ground, and between (B1) and chassis ground as
The measured resistance between connector (B1) and chassis ground is 1 Ohm or less. The short
to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
Troubleshooting Instructions
TROUBLESHOOTING INSTRUCTIONS
TROUBLESHOOTING PROCEDURES
Turn on all the components in the problem circuit to check the accuracy of the customer's
complaints. Note the symptoms. Do not begin disassembly or testing until you have narrowed down
the probable causes.
Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by
tracing the current paths from the power source through the system components to ground. If you
do not understand how the circuit should work, read the circuit operation text. Also check other
circuits that share with the problem circuit. The name of circuits that share the same fuse, ground,
or switch, for example, are referred to on each diagram. Try to operate any shared circuits you did
not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be
within the wiring used only by the problem circuit. If several circuits fail at the same time, the fuse
or ground Is a likely cause.
Repeat the system check to be sure you have repaired the problem. If the problem was a blown
fuse, be sure to test all of the circuits on that fuse.
TROUBLESHOOTING EQUIPMENT
VOLTMETER AND TEST LAMP Use a test lamp or a voltmeter on circuits without solid-state units
and use a test lamp to check for voltage. A test lamp is made up of a 12-volt light bulb with a pair of
leads attached. After grounding one lead, touch the other lead to various points along the circuit
where voltage should be present. When the bulb goes on, there is voltage at the point being tested.
CAUTION: A number of circuits Include solid-state modules, such as the Engine Control
Module(ECM), used with computer command control injection. Voltage In these circuits should be
tested only with a 10-megaohm or higher impedance digital multimeter. Never use a test lamp on
circuits that contain solid state modules. Damage to the modules may result
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4466
A voltmeter can be used in place of a test lamp. While a test lamp shows whether the voltage is
present or not, a voltmeter indicates how much voltage is present
SELF-POWERED TEST LAMP AND OHMMETER Use a self-powered test lamp or an ohmmeter
to check for continuity. The ohmmeter shows how much resistance there is between two points
along a circuit. Low resistance means good continuity.
CAUTION: Never use a self-powered teat lamp on circuits that contain solid state modules.
Damage to these modules may result.
An ohmmeter can be used in place of a self-powered test lamp. The ohmmeter shows how much
resistance there is between two points along a circuit. Low resistance means good continuity.
Circuits which include any solid-state devices should be tested only with a 10-megaohm or higher
impedance digital multimeter. When measuring resistance with a digital multimeter, the battery
negative terminal should be disconnected. otherwise, there may be incorrect readings. Diodes and
solid-state devices in a circuit can make an ohmmeter give a false reading. To find out if a
component is affecting a measurement, take one reading, reverse the leads and take a second
reading. If different the solid-state device is affecting the measurement.
A jumper wire is made up of an in-line fuse holder connected to a set of test leads. This tool is
available with small clamp connectors providing adaption to most connectors without damage.
CAUTION: Do not use a fuse with a higher range than the specified fuse that protects the circuit
being tested. Do not use this tool in any situation to substitute an input or output at the solid-state
control module, such as ECM, TCM, etc.
SHORT FINDER A short finder is available to locate a short to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows you the location of the short through body
trim or sheet metal.
TROUBLESHOOTING TEST
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4467
1. TESTING FOR VOLTAGE
This test measures voltage in a circuit. When testing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead, probe the connector from the back (backprobe).
Always check both sides of the connector because dirt and corrosion between its contact surfaces
can cause electrical problems. A. Connect one lead of a test lamp or voltmeter to a ground. if you
are using a voltmeter, be sure it is the voltmeter's negative test lead you have
connected to ground.
B. Connect the other lead of the test lamp or voltmeter to a selected test point (connector or
terminal). C. If the test lamp glows, there is voltage present. If you are using a voltmeter, note the
voltage reading. A loss of more than 1 volt from
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or
ohmmeter to one end of the part of the circuit you wish to test. If you are using an ohmmeter,
hold the leads together and adjust the ohmmeter to read zero ohms.
C. Connect the other lead to the other end. D. If the self-power test lamp glows, there is continuity.
If you are using an ohmmeter, low or zero resistance means good continuity.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4468
3. TESTING FOR SHORT TO GROUND
A. Disconnect the battery negative terminal. B. Connect one lead of a self-powered test lamp or an
ohmmeter to the fuse terminal on the load side. C. Connect the other lead to a ground. D.
Beginning near the fuse block move the hamess from side to side.Continue this procedure (about
six inches apart) while watching the
E. When the self-powered test lamp glows, or ohmmeter registers,there is a short to a ground in
the wiring near that point.
A. Remove the blown fuse. Leave the battery connected. B. Connect the short finder across the
fuse terminals. C. Close all switches in series in the circuit that is being testing. D. Turn on the
short circuit locator. It sends pulses of current to the short. This creates a pulsing magnetic field
around the wiring between the
E. Beginning at the fuse box, slowly move the short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
body trim. As long as the meter is between the fuse and the short, the needle will move with each
current pulse. Once the meter is moved past the point of the short, the needle will stop moving.
Check around this area to locate the cause of the short circuit.
Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4469
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
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Component Information > Diagrams > Diagram Information and Instructions > Page 4472
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44 33
Body Control Module (BCM) System (1)
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Hyundai Sonata Workshop Manual (V6-3.3L (2006))
Hyundai Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 4474
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