2012 Hyundai Sonata Service and Repair Manual

This 2012 Hyundai Sonata Service & Repair Manual Covers

• Complete factory workshop procedures
• Factory diagnostic information
• Component removal and installation
• Repair and overhaul procedures
• Technical specifications
• Factory maintenance schedules
• Factory wiring diagrams
• Torque specifications
• Fuse and relay information
• Diagnostic flow charts

Engine Options

Petrol

• 2.0L Theta II MPI Inline-4
• 2.4L Theta II GDI Inline-4

Hybrid

• 2.4L Theta II Hybrid (HEV)

Transmission Options

• 6-speed manual transmission (selected markets)
• 6-speed automatic transmission
• 6-speed Hybrid Automatic Transmission (HEV)

Engine and Drivetrain Repair Coverage

• Engine overhaul procedures
• Cylinder head servicing
• Timing chain inspection and replacement
• Gasoline Direct Injection (GDI) diagnostics
• Multi-Point Fuel Injection (MPI) diagnostics
• Hybrid engine management diagnostics
• Fuel system diagnostics
• Ignition system servicing
• Cooling system repairs
• Lubrication system servicing
• Intake and exhaust servicing
• Emissions system diagnostics
• Manual transmission servicing
• Automatic transmission diagnostics
• Hybrid transmission servicing
• Driveshaft servicing
• CV joint inspection and repair

Powertrain Covered

• 2.4L Theta II Hybrid petrol engine
• Permanent magnet synchronous motor
• Lithium-polymer high-voltage battery
• Hybrid Control Unit (HCU)
• Battery Management System (BMS)
• Hybrid starter-generator
• Inverter assembly
• DC-DC converter
• Regenerative braking system

Electric Drivetrain Repair Coverage

• High-voltage battery diagnostics
• Battery Management System diagnostics
• Hybrid Control Unit diagnostics
• Electric drive motor diagnostics
• Inverter diagnostics
• High-voltage cable inspection
• DC-DC converter diagnostics
• Hybrid cooling system servicing
• Regenerative braking diagnostics
• High-voltage isolation testing

Hybrid and EV Technologies

• High-voltage battery diagnostics
• Hybrid system diagnostics
• Battery Management System diagnostics
• Electric motor diagnostics
• Inverter diagnostics
• DC-DC converter diagnostics
• Regenerative braking diagnostics
• High-voltage safety procedures

Chassis, Steering and Suspension

• Front MacPherson strut suspension servicing
• Rear multi-link suspension servicing
• Electronic power steering diagnostics
• Steering rack servicing
• Steering column servicing
• Shock absorber replacement
• Coil spring inspection
• Wheel bearing servicing
• Stabiliser bar servicing
• Wheel alignment specifications

Braking Systems

• ABS diagnostics
• Electronic Stability Control diagnostics
• Traction Control System diagnostics
• Regenerative braking diagnostics (HEV)
• Brake hydraulic system bleeding
• Brake booster servicing
• Front and rear disc brake servicing
• Wheel speed sensor diagnostics

Electrical Systems and Wiring

• Complete factory wiring diagrams
• Engine management system
• Hybrid system wiring (HEV)
• High-voltage system wiring (HEV)
• CAN communication network diagnostics
• Charging system diagnostics
• Starting system diagnostics
• Instrument cluster diagnostics
• Immobiliser diagnostics
• Smart key diagnostics (where equipped)
• Lighting system diagnostics
• Audio and navigation wiring
• Power window diagnostics
• Power mirror diagnostics
• Central locking diagnostics

Air Conditioning and HVAC

• Manual air conditioning servicing
• Automatic climate control diagnostics
• Electric A/C compressor diagnostics (HEV)
• Refrigerant system repairs
• HVAC control module diagnostics
• Blower motor servicing
• Air distribution system servicing

Body, Interior and Restraint Systems

• Body panel removal and installation
• Dashboard removal procedures
• Interior trim servicing
• Power seat servicing
• SRS airbag diagnostics
• Seat belt pretensioner servicing
• Smart key diagnostics
• Rain sensor diagnostics (where equipped)

Diagnostics and Troubleshooting

• Factory diagnostic flow charts
• Symptom-based troubleshooting
• Hybrid system diagnostics
• Scan tool diagnostics
• Sensor testing procedures
• Actuator testing
• CAN communication diagnostics
• Electrical fault isolation
• ECU programming procedures
• Component inspection procedures

Common Error Codes Covered

Engine Codes

• P0016 — Crankshaft Position–Camshaft Position Correlation (Bank 1 Sensor A)
• P0106 — Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance
• P0171 — System Too Lean (Bank 1)
• P0191 — Fuel Rail Pressure Sensor Range/Performance
• P0300 — Random/Multiple Cylinder Misfire Detected
• P0335 — Crankshaft Position Sensor “A” Circuit
• P0420 — Catalyst System Efficiency Below Threshold (Bank 1)
• P0442 — EVAP System Leak Detected (Small Leak)

Transmission Codes

• P0700 — Transmission Control System Malfunction
• P0711 — Transmission Fluid Temperature Sensor Range/Performance
• P0722 — Output Speed Sensor No Signal
• P0741 — Torque Converter Clutch Performance or Stuck Off

EV Powertrain Codes

• P0A0D — High Voltage System Interlock Circuit High
• P0A7F — Hybrid Battery Pack Deterioration
• P0A92 — Hybrid Motor Performance

ABS and Chassis Codes

• C1200 — Front Left Wheel Speed Sensor Signal Fault
• C1210 — Rear Left Wheel Speed Sensor Signal Fault
• C1260 — Steering Angle Sensor Calibration Required

Network Communication Codes

• U0001 — High Speed CAN Communication Bus
• U0293 — Lost Communication With Hybrid Powertrain Control Module

Body Control Codes

• B1326 — Battery Voltage Low
• B1602 — Smart Key Authentication Failure

Plus many other codes included in the manual.

Fuse Box Diagram

• Engine compartment fuse box layout
• Interior fuse box layout
• High-voltage fuse locations (HEV)
• Relay locations
• Fuse identification charts
• Fuse amperage specifications
• Power distribution diagrams

Wiring Diagrams

• Engine management system
• Fuel injection system
• Hybrid powertrain system (HEV)
• High-voltage battery system (HEV)
• Automatic transmission
• Hybrid transmission
• ABS/ESC system
• Air conditioning system
• SRS airbag system
• Instrument cluster
• Lighting system
• Smart key system
• Immobiliser system
• Audio and navigation system
• CAN communication network
• Power windows
• Central locking

Serpentine Belt and Timing System Information

• Accessory drive belt routing
• Serpentine belt inspection procedures
• Belt replacement procedures
• Timing chain inspection
• Timing chain replacement procedures
• Timing chain alignment specifications

Torque Specifications

• Engine fastener torque values
• Cylinder head torque specifications
• Main bearing torque values
• Connecting rod torque values
• Transmission torque specifications
• Suspension torque specifications
• Steering component torque values
• Brake system torque values
• Wheel nut torque specifications
• High-voltage component torque specifications (HEV)

Maintenance and Service Information

• Factory scheduled maintenance intervals
• Engine oil and filter replacement
• Transmission fluid servicing
• Engine coolant replacement
• Inverter coolant replacement (HEV)
• Brake fluid replacement
• Spark plug replacement
• Engine air filter replacement
• Cabin air filter replacement
• Serpentine belt inspection
• High-voltage battery inspection (HEV)
• Tyre rotation procedures
• Wheel alignment checks

Who Is This Manual For?

• New Zealand automotive workshops
• Independent repair garages
• Automotive technicians
• Hybrid vehicle repair specialists
• Auto electricians
• Diagnostic specialists
• Fleet maintenance teams
• DIY owners
• Automotive training institutions