2003 Hyundai Sonata Service and Repair Manual
This fits the 2003 Sonata specifically: the engines and trims Hyundai actually built for that model year, rather than a range spanning adjacent years.
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
- GL
- GLS
- LX
Known issues on the 2003 Sonata. Six recalls are on federal record for this model year. Two concern gasoline fuel storage: one cites a failure to comply with the requirements of Federal Motor Vehicle Safety Standard No. 301, "Fuel System Integrity," because a valve on the fuel tank assembly may not close properly, and the other covers a fuel tank assembly valve that may not close properly, with the hazard arising if a vehicle in that condition were to roll over. In both, fuel spillage in the presence of an ignition source may result in a fire. Two more are interior door handle latch recalls, one covering 91,350 model year 2002-2003 Sonata vehicles and one covering 82, where repeated use of the interior door handle may cause wear of the chrome plating; the consequences on record are laceration injuries to anyone using the door handle, and a sharp edge that could lacerate or otherwise injure a vehicle occupant. A fifth is a suspension recall on 188,282 model year 2001-2004 Sonata and model year 2001-2004 XG300 and XG350 vehicles originally sold in or currently registered in states including Connecticut, Delaware, Illinois, Indiana and Iowa, where the consequence on record is that the vehicle may lose drive power to the wheels. The sixth applies to cars equipped with a traction control system: if the T125/70D-15 compact spare tire is installed on a front wheel position, the TCS may inadvertently activate, which will cause automatic application of the brake at the wheel. Owners have filed 247 complaints for the year and Hyundai has issued 70 technical service bulletins. The factory diagnostic and repair procedures behind each of those systems are here.
From a fuel tank valve check to a suspension inspection on an affected car, or any of the 70 bulletin repairs, it keeps you on the OEM procedure and the correct specification for this 2003 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
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.
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.
THIS MAY INFLICT LACERATION INJURIES TO ANYONE USING THE DOOR HANDLE.
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.
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.
A SHARP EDGE COULD LACERATE OR OTHERWISE INJURE A VEHICLE OCCUPANT.
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.
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.
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.
FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
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.
FUEL SPILLAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
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 76 technical service bulletins on file with NHTSA.
TWO DAYS AFTER MY GRANDMOTHER PURCHASED A 2003 HYUNDAI SONATA, SHE WAS INVOLVED IN A MINOR ACCIDENT. THE CAR WAS TRAVELING AT 45 MPH WHEN IT REAR ENDED ANOTHER VEHICLE. THE AIRBAG NEVER DEPLOYED AND AS A RESULT, SHE BROKE HER BREAST BONE AND AS OF TODAY, IS STILL HOSPITALIZED FROM THE ACCIDENT. *TR
WHILE DRIVING SOUTH ON US68, AN ONCOMING NORTHBOUND CONCRETE TRUCK TURNED DIRECTLY IN FRONT OF US. WHEN WE HIT, THE PASSENGER'S SHOULDER HARNESS OF MY 2003 HYUNDAI SONATA FAILED TO "LOCK". I WAS THROWN AGAINST THE DASH AND THEN THE AIRBAG DEPLOYED DIRECTLY AGAINST MY CHEST. MY WIFE'S AIRBAG (SHE WAS DRIVING) DEPLOYED SLIGHTLY FASTER, BUT LATE ENOUGH THAT IT OPENED UNDER HER CHIN AND POPPED HER HEAD BACK. SHE HAS THREE DAMAGED DISKS IN HER NECK (TWO HERNIATED AND ONE BULGING). MY SHOULDER HA
CAR STOPPED IN FRONT OF US TO TURN LEFT WITH NO BRAKE LIGHTS AND NO BLINKER. WHEN WE REALIZED HE WAS STOPPED WE IMMEDIATELY HIT THE BRAKES. THE SURFACE (CONCRETE) ON THE BRIDGE WAS SLICK AND DID NOT ALLOW US TO HAVE TRACTION. WE SKIDDED APPROX 65 FEET AND REAR-ENDED THE CAR AT APPROX. 40-45 MPH. PASSENGER FRONT AIR BAD FAILED TO DEPLOY. DRIVERS SIDE DEPLOYED. *NM
WE WERE INVOLVED IN AN ACCIDENT AND NONE OF THE AIRBAGS PROPERLY DEPLOYED IT ONLY FELL OUT OF THE SEAT ON THE PASSENGER SIDE OF THE CAR AND IT DEPLOYED FLAT NO AIR IN IT OR NOTHING. MY FIANCEE WAS INJURED AS WELL AS MYSELF AND WE ARE CURRENTLY BEING TREATED FOR INJURIES SUSTAINED BY THE ACCIDENT... *JS
WHILE DRIVING 55 MPH CONSUMER'S VEHICLE COLLIDED WITH THE VEHICLE IN FRONT. UPON IMPACT, BOTH FRONTAL AIR BAGS FAILED TO DEPLOY. DRIVER SUSTAINED MAJOR INJURIES, AND WAS TRANSPORTED TO A HOSPITAL BY THE PRENTS. VEHICLE WAS TOWED TO A GARAGE FOR INSPECTION. *AK.....THE WHOLE DASHBOARD CAME FORWARD AND EVERYTHING INSIDE VEHICLE BROKE, AND AIR BAGS DID NOT DEPLOY. CONSUMER'S SON COMPLAINED OF BACK/LEG, AND ARM INJURIES, WAS TAKEN TO A HOSPITAL. *AK
I WAS TRAVELING ON SUNDAY OCTOBER 31ST ON TO AN EVENT ALONG WITH MY GIRLFRIEND AND HER DAUGHTER. AS WE WERE TRAVELING WESTBOUND ON (MONTVALE AVE) THE MAIN THOROUGHFARE A MAN PULLED OUT INTO TRAFFIC AND TURNED INTO AND CRASHED INTO THE FRONT OF MY HYUNDAI SONATA (2003 LX V6) ALL OF THE PEOPLE IN MY CAR WERE OK SEEING AS WE ALL HAD SEAT BELTS ON. ONE OF THE FAILURES THAT I IMMEDIATELY NOTICED WAS THAT BOTH THE DRIVER SIDE AIRBAG AND THE PASENGER'S AIRBAG DID NOT DEPLOY WHEN WE WERE HIT BY THE
TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT WAS DRIVING APPROXIMATELY 30 MPH WHEN HE CRASHED INTO ANOTHER VEHICLE. THE DRIVER SIDE AIR BAG FAILED TO DEPLOY AND THE SEAT BELT FAILED TO RESTRAIN THE CONTACT. THE CONTACT SUSTAINED INJURIES TO THE CHEST, RIB AND NECK. THE VEHICLE WAS TOWED TO THE INSURANCE TOW-YARD. THE FAILURE AND THE CURRENT MILEAGE WAS 107,000. THE VIN WAS NOT AVAILABLE. UPDATED 11/16/11*LJ
WHILE DRIVING 40 MPH CONSUMER'S VEHICLE COLLIDED WITH THE VEHICLE IN FRONT. UPON IMPACT, BOTH FRONTAL AIR BAGS FAILED TO DEPLOY. DRIVER SUSTAINED MINOR INJURIES. VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION. *AK..... CONSUMER SUSTAINED A BROKEN HNEE CAP AND EXTREME TORSO BRUISING. *AK
DT*: THE CONTACT STATED THE VEHICLE WAS INVOLVED IN A HEAD ON COLLISION AND NONE OF THE AIR BAGS DEPLOYED. WHILE TRAVELING BETWEEN 45-50 MPH ANOTHER VEHICLE SWITCH LINES, CUTTING OFF THE CONTACT. THE CONTACT'S VEHICLE WENT INTO THE LEFT LANE AND HIT A GUARD RAIL ON THE LEFT SIDE OF THE ROAD IMPACTING THE REAR OF THE VEHICLE. THE VEHICLE THEN SPUN AROUND ACROSS BOTH LANES AND HIT THE GUARD RAILS ON THE RIGHT SIDE OF THE ROAD HEAD ON. NONE OF THE AIR BAGS DEPLOYED. THE DEALERSHIP HAS BEEN AL
THE CONSUMER'S HYUNDAI SONATA DEVELOPED THE FOLLOWING PROBLEMS: THE PAINT WAS PEELING, THE SUN ROOF WAS BROKEN, THE PASSENGER SIDE WINDOW WAS INOPERATIVE, THE BRAKES FAILED, THE SEATBELT BROKE, THE ENGINE BLEW UP AND THE AIR BAGS FAILED TO DEPLOY. *MR THE ENGINE SURGED. AS A RESULT OF THE ENGINE BLOWING, THE RIGHT SIDE DISINTEGRATED. *SC *JB
MERGED INTO LEFT LANE ON HIGHWAY GOING ABOUT 65MPH. CAR SPUN TO FACE OPPOSING WAY. HIT WALL ON PASSENGER SIDE, SPUN BACK AROUND AND WENT ACROSS HIGHWAY TO HIT OPPOSITE WALL. CAR HAD BEEN TOTALED AS I WALKED AWAY WITH. *TR
TL* THE CONTACT OWNS A 2003 HYUNDAI SONATA. THE CONTACT STATED THAT THE DRIVER WAS INVOLVED IN A FRONTAL CRASH WHILE DRIVING 20 MPH. THE AIR BAGS DEPLOYED YET THE DRIVER SUSTAINED MINOR CHEST INJURIES. A POLICE REPORT WAS FILED AND THE VEHICLE WAS DESTROYED. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THEY WOULD SEND HIM A PACKET TO FILL OUT AND THEY WOULD DECIDE WHAT THEY WOULD DO. THE VIN WAS UNAVAILABLE. THE CURRENT AND FAILURE MILEAGE WAS APPROXIMATELY 111,000.
IN 2005 WHILE DRIVING MY GIRL FRIENDS 2003 HYUNDAI SONATA, I WENT TO MAKE A LEFT TURN OF A MAIN STREET IN OAKLAND, CA. AND WAS HIT BY A 2006 MERCEDES BENZ OWN THE PASSENGER SIDE. NO AIR BAGS WHERE DEPLOYED AT ALL. $8.000 DOLLARS IN DAMAGE WAS DONE. HYUNDAI CORPORATION NEVER CAME OUT TO LOOK AT THE CAR, BUT RULED THAT THE SENSORS ACTED PROPERLY. THE CAR WA EQUIPPED I BELIEVE WITH FRONT AND SIDE AIR BAGS. *NM
DT*: THE CONTACT STATED WHILE DRIVING ON THE HIGHWAY, ANOTHER VEHICLE ENTERED AND STARTED SPINNING. THE CONTACT MOVED THE VEHICLE TO THE FAR LANE, BUT THE OTHER VEHICLE STILL HIT THE PASSENGER SIDE DOOR. WHEN THIS OCCURRED, NONE OF THE AIRBAGS DEPLOYED. THERE WAS A POLICE REPORT TAKEN AT THE SCENE. BOTH OCCUPANTS WERE WEARING SEATBELTS, BUT THE PASSENGER SUSTAINED MINOR INJURIES INCLUDING A BROKEN FINGER. THE VEHICLE WAS DEEMED TOTALED BY THE INSURANCE COMPANY.
WHILE DRIVING 65 MPH STEERING WHEEL WAS LOOSE, CAUSING THE DRIVER TO HIT A CONCRETE BARRIER. DRIVER DROVE THE VEHICLE TO THE DEALER FOR ANALYSIS, AND MECHANIC COULD NOT DUPLICATE THE PROBLEM. *AK
Showing the 15 most serious of 199 complaints filed with NHTSA.
