Recall 075 - Headlamp Non-Compliance
Group: CAMPAIGNNumber: 06-01-005
Date: JUNE, 2006 Model
Model: 2006 SONATA 2.4L
Subject
HEADLAMP ASSEMBLY REPLACEMENT
SERVICE CAMPAIGN 075
IMPORTANT:
DEALERS MUST PERFORM THIS CAMPAIGN ON ALL AFFECTED VEHICLES PRIOR TO CUSTOMER RETAIL DELIVERY AND WHENEVER AN AFFECTED VEHICLE IS IN THE SHOP FOR ANY MAINTENANCE OR REPAIR.
IMPORTANT:
WHEN A VEHICLE ARRIVES AT THE SERVICE DEPARTMENT, ACCESS HYUNDAI MOTOR AMERICA'S "WARRANTY VEHICLE INFORMATION" SCREEN VIA DCS INTERACTIVE OR DCS ON-LINE TO IDENTIFY OPEN CAMPAIGNS.
DESCRIPTION:
Some 2006 MY Sonata vehicles produced in Korea with 2.4L engines may contain headlamp assemblies that do not meet the turn signal luminous intensity requirements of Federal Motor Vehicle Safety Standard (FMVSS) 108.
This bulletin will describe the procedure on how to replace and aim the new headlamp assemblies.
VEHICLES AFFECTED:
^ Model: 2006 MY Sonata vehicles produced in Korea with 2.4L engines
^ Affected production date range: Produced from July 3, 2005 to July 11, 2005
PART REQUIRED:
SERVICE PROCEDURE:
Headlamp Replacement
1. Assure the vehicle battery is fully charged.
2. Record the radio station presets and disconnect the vehicle negative battery cable from the battery.
3. Loosen the 3 headlamp mounting screws (A) and disconnect the headlamp connector (B).
4. Remove the existing headlamp and install with the new headlamp.
5. Repeat procedure for the left headlamp.
Headlamp Aiming:
6. Connect the battery negative terminal and check the following before aiming the headlamps:
A. Inflate the tires to the specified pressure.
B. Position the vehicle on a level surface perpendicular to a flat wall 118 inches (3,000 mm) away from the front headlamp lens. Verify that the vehicle does not lean to one side.
C. Remove any loads from the vehicle except for the spare tire and jack. Fuel, engine oil and coolant should be fully filled.
D. Check the suspension for free operation. Bounce the front suspension several times by pushing the front end downwards and releasing it. Repeat for the rear suspension.
E. Clean the headlamp lenses.
F. Check the ride height (H1IH2), the height between the headlamp bulb center and ground (H1IH2), and the distance between each headlamp bulb center (W1/W2). Refer to the illustrations and tables.
7. With the headlamp low beam on (fog lights off), rotate the headlamp vertical aiming screw so that the horizontal Cut-Off Line is 0.8 inch (21 mm) below the horizontal headlamp centerline.
NOTE:
Verify the location of the headlamp vertical aiming screw by referring to the below photos.
8. Reprogram the radio stations and reset the clock.
CAMPAIGN CLAIM INFORMATION:
NOTE:
Submit claim using the Campaign Claim Entry Screen.