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2002 Hyundai Sonata Service and Repair Manual
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$42.99 USD
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Covers all 2002 Sonata trims — Base Sedan 4-Door, GLS Sedan 4-Door, LX Sedan 4-Door ·
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$42.99
2002 Hyundai Sonata Service and Repair Manual
Regular price
$42.99 USD
Unit price
Fitment for this 2002 Hyundai Sonata factory service and repair manual is set by the exact year, engine and trim you own, so the Hyundai specifications you work to are the ones published for this car rather than figures carried over from an adjacent model year.
Engines covered
- 2.4L inline-four — DOHC, naturally aspirated, gasoline
- 2.7L V6 — DOHC, naturally aspirated, gasoline
Body styles covered
- 4-door sedan
Trims covered
- Base
- GLS
- LX
Known issues on the 2002 Sonata. Six recalls are on federal record for this model year. Two concern the fuel tank assembly: a valve on the tank may not close properly, and one of the two is recorded as a failure to comply with Federal Motor Vehicle Safety Standard No. 301, "Fuel System Integrity". If a vehicle with a fuel tank assembly valve that is not properly closed were to roll over, fuel spillage in the presence of an ignition source may result in a fire. Two more cover the interior door latch handles, where repeated use may wear the chrome plating and a thin top edge on the handle can leave a sharp edge that could lacerate or otherwise injure an occupant. Another involves the temporary spare: on cars with traction control, if the T125/70D-15 compact spare tire is installed on a front wheel position the TCS may inadvertently activate, which causes automatic application of the brake. The last is a suspension recall covering cars originally sold in or currently registered in the states of Connecticut, Delaware, Illinois, Indiana and Iowa, among others, where the vehicle may lose drive power to the wheels. NHTSA has 407 owner complaints on record for the year and Hyundai has issued 82 technical service bulletins. The factory diagnostic and repair procedures behind each of those systems are here.
Fuel tank valve work, an interior door handle replacement or a suspension inspection each come back to a documented Hyundai procedure and the correct specification for your 2002 Sonata.
HYUNDAI IS RECALLING 188,282 MY 2001-2004 SONATA AND MY 2001-2004 XG300 AND XG350 VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE JURISDICTIONS DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUB-FRAME ON THE VEHICLES, AND MAY RESULT IN THINNING OR PERFORATION OF THE SUB-FRAME STEEL. THE CORROSION IS FREQUENTLY VISIBLE AND OFTEN DISCOVERED DURING INSPECTION OR ROUTI
Consequence
IF THAT HAPPENS, THE VEHICLE MAY LOSE DRIVE POWER TO THE WHEELS, AND THE FRONT WHEEL MAY MAKE CONTACT WITH THE FENDER OR WHEEL WELL, THEREBY INCREASING THE RISK OF A CRASH.
Remedy
DEALERS WILL MEASURE THE THICKNESS OF THE FRONT SUB-FRAME AND INSPECT THE FRONT SUB-FRAME FOR CORROSION DAMAGE AND, IF NECESSARY, THE FRONT SUB-FRAME WILL BE REPLACED WITH A NEW SUB-FRAME THAT INCORPORATES ADDITIONAL HOLES IN THE UPPER AND LOWER PANELS. IF THE FRONT SUB-FRAME DOES NOT REQUIRE REPLACEMENT, THE DEALER WILL ADD DRAINAGE HOLES TO THE SUB-FRAME AND WILL TREAT THE SUB-FRAME WITH RUST-PROOFING MATERIAL TO STOP THE CORROSION PROCESS. THIS PROCEDURE WILL BE PERFORMED FREE OF CHARGE. T
HYUNDAI IS RECALLING 91,350 MY 2002-2003 HYUNDAI SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATE. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING, THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.
Consequence
THIS MAY INFLICT LACERATION INJURIES TO ANYONE USING THE DOOR HANDLE.
Remedy
DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JUNE 2009. OWNERS MAY CONTACT HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.
ON CERTAIN PASSENGER VEHICLES, THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SIDE IMPACT AIR BAG SATELLITE SENSORS MAY BE TOO SENSITIVE TO SOME LATERAL ACCELERATIONS THAT ARE NOT CAUSED BY SIDE IMPACTS TO THE VEHICLE, SUCH AS FORCEFULLY SLAMMING A DOOR CLOSED.
Consequence
INADVERTENT DEPLOYMENT OF A SRS SIDE IMPACT AIR BAG WHEN A SIDE IMPACT CRASH HAS NOT OCCURRED COULD INCREASE THE RISK OF INJURY TO THE SEAT OCCUPANT.
Remedy
DEALERS WILL REPLACE THE SIDE IMPACT AIR BAG SATELLITE SENSORS. OWNER NOTIFICATION BEGAN JULY 8, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
HYUNDAI IS RECALLING 82 MODEL YEAR 2002-2003 SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATING. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.
Consequence
A SHARP EDGE COULD LACERATE OR OTHERWISE INJURE A VEHICLE OCCUPANT.
Remedy
DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 16, 2009. OWNERS MAY CONTACT HYUNDAI OF PUERTO RICO AT 1-787-999-3333.
ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH A TRACTION CONTROL SYSTEM (TCS), IF THE T125/70D-15 COMPACT SPARE TIRE IS INSTALLED ON A FRONT WHEEL POSITION, THE TCS MAY INADVERTENTLY ACTIVATE BEGINNING AT SPEEDS OF 20 MPH.
Consequence
INADVERTENT ACTIVATION OF THE TCS WILL CAUSE AUTOMATIC APPLICATION OF THE BRAKE AT THE WHEEL WHERE THE COMPACT SPARE TIRE IS INSTALLED. INADVERTENT BRAKE APPLICATION COULD CAUSE OVERHEATING AND DAMAGE TO THE BRAKE, AND MAY PREVENT THE VEHICLE FROM BEING DRIVEN AT SPEEDS ABOVE 20 MPH, WHICH COULD RESULT IN A CRASH.
Remedy
DEALERS WILL REPLACE THE SPARE TIRE WITH A NEW LARGER DIAMETER T125/80R-15 COMPACT SPARE TIRE AND A NEW TIRE PRESSURE LABEL WILL BE INSTALLED ON THE DRIVER'S DOOR TO PROVIDE INFORMATION APPLICABLE TO THE T125/80R-15 COMPACT SPARE TIRE. VEHICLES PRODUCED FROM NOVEMBER 15, 2002 THROUGH DECEMBER 16 2002, ALREADY CONTAIN T125/80R-15 COMPACT SPARE TIRES, WILL ONLY REQUIRE NEW TIRE PRESSURE LABELS. OWNER NOTIFICATION BEGAN JUNE 30, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN
SOME PASSENGER VEHICLES CONTAIN A FUEL TANK ASSEMBLY VALVE THAT MAY NOT CLOSE PROPERLY. IF A VEHICLE WITH A FUEL TANK ASSEMBLY VALVE THAT IS NOT PROPERLY CLOSED WERE TO ROLL OVER, FUEL SPILLAGE MAY OCCUR.
Consequence
FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
Remedy
DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. OWNER NOTIFICATION BEGAN ON JUNE 30, 2004. OWNERS SHOULD CONTACT HYUNDAI AT 1-800-633-5151.
CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 301, "FUEL SYSTEM INTEGRITY" A VALVE ON THE FUEL TANK ASSEMBLY MAY NOT CLOSE PROPERLY. IF A VEHICLE ROLLS OVER AND THE FUEL TANK ASSEMBLY VALVE IS NOT PROPERLY CLOSED, FUEL SPILLAGE MAY OCCUR.
Consequence
FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
Remedy
DEALERS WILL INSTALL AN ADDITIONAL FUEL TANK ASSEMBLY VALVE. THE RECALL BEGAN ON OCTOBER 5, 2004. OWNERS SHOULD CONTACT HYUNDAI DE PUERTO RICO AT 1-800-981-0188.
The National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous drivers-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN). These infla
The National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driverside airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN),
This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside th
This bulletin contains information about the proper removal of the windshield wiper blade protective cover on all models. If the protective cover is not removed correctly, there is a possibility of the rubber insert and rail spring becoming
This bulletin provides important checkpoint guidelines when performing engine oil and filter change services.
Hyundai applies a Paint Protection Film (PPF) on new vehicles before delivery to dealerships. It provides a barrier between the paint and contaminants, such as rail dust, acid rain, and industrial fallout. In rare cases, the paint can becom
This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside th
Effective June 2, 2008, Federal Motor Vehicle Safety Standard 110 (FMVSS 110) established a threshold for correcting load carrying capacity information indicated on tire placards when vehicle weight has been increased before retail sale. Th
Showing the 8 most recent of 88 technical service bulletins on file with NHTSA.
WHILE DRIVING 30-35 MPH VEHICLE WAS HIT ON DRIVER SIDE, BETWEEN DRIVER DOOR AND PASSENGER DOOR. BOTH FRONT AIR BAGS DEPLOYED, SIDE AIR BAG ON DRIVER SIDE DID NOT. DRIVER HIT HIS HEAD ON WINDOW. DAMAGE TO VEHICLE UNKNOWN AT THIS TIME. TS
VEHICLE WAS HIT ON DRIVER SIDE DOOR(S) - VEHICLE WAS ROTATED 180 DEGREES FROM THE FORCE OF THE IMPACT. NECK AND BACK INJURIES. BOTH FRONT AIR BAGS DEPLOYED, SIDE AIR BAG DID NOT DEPLOY. *AK
MY 2002 HYUNDAI SONATA AIR BAG LIGHT HAS BEEN ON SINCE 2009 I HAVE BOUGHT IT TO ONE MECHANIC HE CLEANED AND TIGHTENED THE AIR BAG HARNESS UNDER DRIVER AND PASSENGER SEAT THEY STAYED OUT BRIEFLY AND CAME BACK ON SHORTLY THERAFTER. BROUGHT IT TO ANOTHER MECHANIC AND HE COULDN T FIX IT. CALLED LOCAL DEALER AND THEY SAID THEIR ARE NO ACTIVE RECALLS AND COULD BE ALOT OF MONEY. I LOOKED ONLINE AND OTHER 2002 HYUNDAI SONATA OWNERS WENT TO DEALER S AND PAID ALOT MONEY AND LIGHT KEPT COMING ON.JULY 12,
IN A FRONTAL COLLISION NONE OF THE AIR BAGS DEPLOYED,CASUING MAJOR INJURIES TO DRIVER AND PASSENGER.*AK *YH
DRIVING AT 25 - 30 MPH I WAS HIT HEAD ON BY ANOTHER MID SIZE VEHICLE. I SUSTAINED HEAD, NECK, AND BACK INJURIES AND MY AIRBAGS DID NOT DEPLOY. MY CONCERN IS THAT I HAVE A 2003 HYUNDAI SONATA WILL THOSE BAGS NOT DEPLOY IN A HEAD ON? MY WIFE AND CHILD DRIVE THE 2003 . I AM VERY CONCERNED. MY INSURANCE COMPANY WANT TO "REPAIR" MY VEHICLE THAT FAILED.
TL*THE CONTACT OWNED A 2002 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 15 MPH THE VEHICLE WAS INVOLVED IN A CRASH IN WHICH THE AIR BAGS DID NOT DEPLOY. A POLICE REPORT WAS FILED AND THE DRIVER WAS REPORTED INJURED. THE VEHICLE WAS DESTROYED AND TOWED TO A JUNK LOT. THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 80,000.
CONSUMER'S VEHICLE WAS HIT ON DRIVER'S DOOR. SPEED OF IMPACT WAS 45 MPH. UPON IMPACT, DRIVER'S SIDE AIRBAG DID NOT DEPLOY. CONSUMER SUFFERED NECK AND BACK INJURIES. $ 6000.00 DAMAGE TO VEHICLE.*AK
SINGLE VEHICLE ROLLOVER; DRIVERS' DOOR UNLATCHED AND CAME OPEN DURING THE ROLLOVER. *JB
WE RECENTLTY PURCHASED A USED BUT SHOWROOM CONDITION HYUNDAI SONATA WITH SOMEWHERE AROUND 29,000 MILES ON IT FROM A DEALERSHIP. AFTER ABOUT THREE WEEKS MY SON HAD TO LEAVE IT IN A PARKING LOT. THE THROTTLE/CRUISE CONTROL CABLE (EVEN THO HE DID NOT HAVE THE CRUISE CONTROL ON) WAS STUCK. HE THOUGHT THE PROBLEM WAS FIXED SO HEDROVE THE CAR A FEW MORE WEEKS AND WAS ON HIS WAY HOME WHEN THE SAME THING HAPPENED AGAIN ONLY THIS TIME HE RAN INTO A UTILITY POLE. THE CAR WAS DAMAGED PRETTY BADDLY BUT T
I WAS INVOLVED IN A CAR CRASH IN WHICH THE ENTIRE FRONT END OF MY CAR WAS SMASHED FROM THE LEFT FRONT FENDER SHOVING THE HOOD AND FRONT END SO FAR TO THE RIGHT AND IN THAT THE PASSENGER DOOR WOULD NOT OPEN AND THE SIDE AND FRONT AIR BAGS DID NOT DEPLOY AT ALL. I WAS INJURED BY THE DOOR POST. IT WAS A 2002 HUNDAI SONATA..WE ARE AFRAID THAT IT MAY BE A CHILD INVOLVED NEXT TIME THERE IS A FAILURE OF THE SIDE AND FRONT AIRBAGS ON THE SONATA..PLEASE BRING THIS TO SOMEONES ATTENTION TKS LRW
WAS IN ACCIDENT AIRBAG DID NOT DEPLOY. *TR
TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 33 MPH, THE CONTACT'S VEHICLE STRUCK A POTHOLE. AS A RESULT, THE CONTACT VEERED TO THE RIGHT AND CRASHED INTO ANOTHER VEHICLE. THE AIR BAGS DEPLOYED. THE CONTACT SUSTAINED A NECK INJURY THAT REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE SUBFRAME WAS RUSTED AND FAILED TO SUPPORT THE CONTROL ARM. THE TECHNICIAN INFORMED THAT THE SUBFRAME
DT: CALLER GOT INTO CAR, PULLED IT OUT OF GARAGE AND GOT OUT OF IT. WHEN SHE GOT BACK INTO VEHICLE AND PUT IT IN GEAR IT MADE A SCREAMING NOISE AND ACCELERATED. SHE HIT THE BRAKES, BUT THEY DID NOT WORK. SHE TRIED TO STOP THE CAR BY GOING UP A HILL INSTEAD VEHICLE HIT A HOUSE THREE DOORS AWAY. UPON IMPACT, AIR BAGS DID NOT DEPLOY. INSURANCE CLAIMED THAT DEALER SAID THERE NOTHING WAS WRONG WITH CAR. MANUFACTURER HAS NOT BEEN CONTACTED YET. *AK
WAS IN ACCIDENT AIRBAG DID NOT DEPLOY. *TR
WHILE DRIVING 50 MPH THE VEHICLE WAS INVOLVED IN A HEAD ON COLLISION. UPON IMPACT, THE DUAL AIRBAGS DID NOT DEPLOY, INSTEAD THE AIRBAG SENSOR LIGHT CAME ON. *AK THE RADIATOR HAD BROKEN ALSO. *SC
Showing the 15 most serious of 325 complaints filed with NHTSA.
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