2004 Hyundai Sonata Service and Repair Manual
Every figure in this factory service and repair manual for the 2004 Hyundai Sonata is tied to this exact year, engine and trim, so the clearances, torque values and service sequences you work to are the ones Hyundai published for this car and not numbers 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
- GL
- GLS
- LX
Known issues on the 2004 Sonata. One recall is on federal record for this model year, and it falls under suspension. Hyundai recalled 188,282 MY 2001-2004 Sonata and MY 2001-2004 XG300 and XG350 vehicles originally sold in or currently registered in states including Connecticut, Delaware, Illinois, Indiana and Iowa; the consequence on record is that the vehicle may lose drive power to the wheels. Owners have filed 288 complaints for the year and Hyundai has issued 46 technical service bulletins.
From a suspension check on a car covered by that campaign to a 2.7L V6 service interval or a driveability complaint, you stay on the OEM procedure and the correct specification for your specific 2004 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
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 52 technical service bulletins on file with NHTSA.
MY FOOT SLIDE OFF THE BREAK, AND HIT MY VAN IN THE BACK BUMPER IN MY DRIVEWAY AND TWO WEEKS LATER MY AIR BAG LIGHT CAME ON AND NEVER WENT OFF. AT MY HOME, NO REPORTS, OR DAMAGE OTHER THEM CUT ON MY BUMPER DUE TO THE HAUL ON THE VAN.
WE OWN A 2004 HYUNDAI SONATA (109,000 MILES) WE HAD A FRONT END COLLISION WITH SIGNIFICANT DAMAGE. ME AND MY WIFE SUFFERED MINOR INJURIES AND THE AIRBAGS DID NOT DEPLOY. WE FOUND OUT ON THE INTERNET THAT THERE ARE FREQUENT COMPLAINTS IF THIS FAILURE AROUND THE NATION AND ALSO IN MANY HYUNDAI MODELS ACROSS MULTIPLE YEARS. WE ARE FILING THE COMPLAINT SINCE THE ERROR IS CRITICAL AND SEEMS TO BE SYSTEMIC IN HYUNDAI VEHICLES. WE DO NOT KNOW IF NHTSA HANDLES CARS THAT ARE OVER 100,000 MILES BUT WE FEL
DT: THE CONTACT'S VEHICLE WAS INVOLVED IN A CRASH. UPON IMPACT, FRONT AND SIDE AIR BAGS DID NOT DEPLOY. ALSO, THE SEAT BELTS DID NOT RESTRAIN THE CONTACT AND HER PASSENGER IN THE SEATS. THE CONTACT WAS THROWN INTO THE STEERING WHEEL, AND THE PASSENGER HIT THE WINDSHIELD. BOTH SUSTAINED SERIOUS INJURIES AND BROKEN BONES. A POLICE REPORT WAS TAKEN, AND AN INSURANCE REPORT WAS FILED. PICTURES ARE AVAILABLE FOR REVIEW. THE VEHICLE WAS REPAIRED.*AK UPDATED 2/21/2006 - *NM
The contact owns a 2004 Hyundai Sonata. The contact stated her fiance was driving 20-25 MPH on a steep hill with her in the front passenger's side seat. The contact stated that her fiance depressed the brake pedal to come to a complete stop at the stop sign, but the brake pedal went down to the floorboard, and the vehicle failed to respond. The contact's fiance veered to the left and intentionally hit a telephone pole to avoid crashing into a parked vehicle, and to prevent a more severe accident
DT*: THE CONTACT STATED WHILE DRIVING 35 MPH, THE VEHICLE WAS INVOLVED IN A CRASH AND THE AIR BAGS DID NOT DEPLOY. THE VEHICLE WAS STRUCK BROAD SIDED ON THE PASSENGER SIDE BETWEEN BOTH DOORS. BOTH PASSENGERS OF THE VEHICLE WERE WEARING SEAT BELTS AND RECEIVED ONLY MINOR INJURIES. THE VEHICLE WAS ABLE TO BE DRIVEN AWAY FROM THE SCENE. THE POLICE WERE AT THE SCENE OF THE ACCIDENT AND PROVIDED A WRITTEN REPORT; HOWEVER, THE VEHICLE HAS NOT BEEN INSPECTED BY THE INSURANCE COMPANY. UPDATED 5/2/
I WAS INVOLVED IN A CHAIN REACTION COLLISION ON I-10 INTERSTATE. MY VEHICLE RE-ENDED ANOTHER VEHICLE AND NEITHER THE DRIVER'S NOR THE PASSENGER'S AIR BAGS DEPLOYED. FRONT END DAMAGED AND INSURANCE HAS TOTALED MY CAR. BRAKES DID NOT SEEM TO STOP WITH SUFFICIENT FORCE. *TR
TL* THE CONTACT OWNS A 2004 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 5 MPH, SHE APPLIED THE BRAKES AND THE VEHICLE SUDDENLY ACCELERATED FORWARD. THE VEHICLE CONTINUED TO ACCELERATE UNTIL CRASHING INTO THE WALL OF A BUILDING. THE AIRBAGS ONLY DEPLOYED ON THE PASSENGER SIDE. THE POLICE WERE NOTIFIED AND A REPORT WAS AVAILABLE. BOTH THE DRIVER AND PASSENEGER SUSTAINED MINOR BRUISING AND WERE TRANSPORTED TO THE HOSPITAL VIA AMBULANCE. THE VEHICLE WAS TOWED TO AN INDEPENDEN
WAS IN A CAR ACCIDENT ON DECEMBER 04 2011. I HAD SIGNIFICANT FRONT END DAMAGE TO MY VEHICLE DUE TO SOMEONE RUNNING A STOP SIGN. HOWEVER, MY AIRBAGS DID NOT DEPLOY ON FRONT!! ONLY ON THE DRIVER SIDE AND WAS NOT FULL OPEN , VERY CONCERN ON SAFETY! *TR
TL*THE CONTACT OWNS A 2004 HYUNDAI SONATA. WHILE DRIVING APPROXIMATELY 10 MPH, ANOTHER VEHICLE CRASHED INTO THE DRIVER'S SIDE OF THE CONTACT'S VEHICLE. THE DRIVER'S SIDE DOORS WERE COMPLETELY SMASHED IN AND THE FRAME WAS BENT. THE AIR BAGS FAILED TO DEPLOY. THE DRIVER OF THE VEHICLE SUSTAINED MAJOR INJURIES TO HER LEFT SHOULDER. THE PASSENGERS IN THE OTHER VEHICLE WERE UNINJURED. A POLICE REPORT WAS FILED. THE MANUFACTURER STATED THAT THE AIR BAGS OPERATED IN THE MANNER THEY WERE DESIGNED
2004 HYUNDAI SONATA WAS INVOLVED IN A SEVERE SIDE IMPACT, STRUCK BY A DODGE DURANGO. IMPACT WAS CENTERED ON THE DRIVERS SIDE DOOR AND RESULTED IN AN APPROXIMYATE 1 FOOT OF INTRUSION. MAX CRUSH OCCURRED JUST FORWARD OF THE B-PILLAR. B-PILLAR WAS PUSHED INTO THE SEAT AND THE LEADING EDGE OF THE DOOR WAS PUSHED INTO THE STEERING WHEEL. THE HEAD/THORAX BAG LOCATED IN THE DRIVERS SEAT DID NOT DEPLOY. NHTSA SHOULD INSPECT THIS TO SEE WHY THE SIDE AIR BAGS DID NOT DEPLOY. THIS APPEARS TO BE THE
WAS IN A CAR ACCIDENT ON JUNE 21, 2009. I HAD SIGNIFICANT FRONT END DAMAGE TO MY VEHICLE DUE TO SOMEONE RUNNING A STOP SIGN. HOWEVER, MY AIRBAGS DID NOT DEPLOY ON THE PASSENGER OR DRIVER SIDE. *TR
I WAS GOING ABOUT 35 MILES PER HOUR AND REAR ENDED A ANOTHER VEHICLE AND MY DRIVERS AIR BAG DID NOT DEPLOY. I WAS NOT HURT, BUT MY DAUGHTER IN THE BACK SEAT WAS. *NM
CONSUMER APPLIED THE BRAKES, AND THE PEDAL WENT TO THE FLOOR WHILE TRAVELING 40 MPH. CONSUMER'S VEHICLE REAR ENDED ANOTHER VEHICLE. UPON IMPACT, AIR BAGS DID NOT DEPLOY DRIVER'S SEAT BELT BECAME UNATTACHED IN THE COLLISION.*AK THE DRIVER SUSTAINED INJURIES AND WENT TO THE HOSPITAL BY CAR. THE VEHICLE WAS TOWED AND TOTALED OUT BY THE INSURANCE COMPANY. PLEASE FILL IN ADDITIONAL INFORMATION.
I OPERATE A 2004 HYUNDAI SONATA. IT EQUIPPED WITH SHIFTRONIC FEATURE, WHERE YOU ABLE TO OVERDRIVE A REGULAR AUTOMATIC TRANSMISSION BY MANUALLY SWITCHING TO DESIRED GEAR. HOWEVER, IT HAS OWN LOGIC NOT TO ALLOW YOU TO SWITCH TO INAPPROPRIATE GEAR LEADING TO OVERSTRESS AND/OR DAMAGE ENGINE OR TRANSMISSION. WHILE DRIVING ON SLIPPERY ROAD I USED ABOVE MENTIONED FEATURE TO SLOW DOWN A CAR WHEN APPROACHING AN INTERSECTION (SO-CALLED ENGINE BRAKE). AT SAME TIME I USED REGULAR BRAKES TOO SINCE ENGINE
THE AC/HEATING ELECTRIC [FAN] CONTROL COMES ON WHEN IT WANTS TO BUT WILL NOT ACTIVATE WHEN TURNED ON. WHEN TAKEN TO A MECHANIC ON 3 OCCASIONS, IT ACTIVATES AND REMAINS ON FOR DAYS THEN STOPS AND WILL NOT COME ON AGAIN. MECHANICS DO NOT WANT TO WORK ON IT UNLESS IT DOES NOT WORK AT ALL. EVERYONE WANTS TO "INVESTIGATE" AND CHARGE ME ACCORDINGLY BUT NO ONE WANTS TO TELL ME THE ACTUAL PROBLEM. THIS HAD BEEN GOING ON FOR MANY MONTHS ON MY CAR, AS WELL AS OTHER HYUNDAI MODELS. THE UNRESOLVED SITUA
Showing the 15 most serious of 202 complaints filed with NHTSA.
