Engine Compartment ................................................... 6-2Daily Operating Checks ............................................... 6-4Engine Oil ..................................................................... 6-4Engine Oil and Filter Replacement .............................. 6-8Engine Coolant Checking and Replacing .................... 6-9Spark Plug ...................................................................6-12Changing the Air Cleaner Filter ...................................6-13Manual Transmission Lubricant ..................................6-16Automatic Transmission Lubricant ..............................6-17Brake System Checking .............................................6-19Checking the Clutch Fluid ...........................................6-20Air Conditioning System Maintenance ........................6-21Checking Engine Drive Belts ......................................6-24Fusible Links ...............................................................6-25Battery Maintenance ...................................................6-27Checking Electric Cooling Fans .................................6-28Fuel Filter .....................................................................6-30Power Steering Fluid Level .........................................6-29Replacing Headlight Bulbs ..........................................6-31Headlight Aiming Adjustment ......................................6-33Bulb Wattages .............................................................6-35Fuse Panel Description ...............................................6-36

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6 OWNER MAINTENANCE

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1. Power steering fluid reservoir2. Brake fluid reservoir3. Engine cover4. Battery5. Fuse and relay box

6. Windscreen washer fluid reservoir7. Air cleaner filter8. Radiator cap9. Engine oil filler cap

10.Automatic transmission fluid leveldipstick (Vehicle with AutomaticTransmission)

11.Engine oil level dipstick12.Coolant reservoir cap

G010A01HP-EAT

Petrol Engine Compartment (3.5 V6)

CAUTION:When inspecting or servic-ing the engine, you shouldhandle tools and otherheavy objects carefully sothat the plastic cover of theengine is not damaged.

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ENGINE COMPARTMENT

G010A01HP-E

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G010C01HP-EAT

Diesel Engine Compartment (2.9 CRDi)

1. Brake fluid reservoir2. Clutch fluid reservoir (Not all models)3. Engine oil level dipstick4. Engine cover

5. Engine oil filler cap6. Battery7. Fuse and relay box8. Windscreen washer fluid reservoir9. Air cleaner filter

10.Radiator cap11.Fuel filter12.Power steering fluid reservoir13.Coolant reservoir cap

CAUTION:When inspecting or servic-ing the engine, you shouldhandle tools and otherheavy objects carefully sothat the plastic cover of theengine is not damaged.

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G010C01HP-E

6 OWNER MAINTENANCE

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G030B03HP-EAT

Recommended Oil1. Petrol Engine(1) Select engine oil of the proper SAE

viscosity number according to theatmospheric temperature.Recommended viscosity is givenin the following illustration.

(2) A multi grade oil having a specifi-cation which meets A.P.I. specifi-cation of SG, SH or ABOVE isrecommended.

DAILY OPERATING CHECKS

SG020B1-E

The following items should be checkedon a daily basis or whenever thevehicle is refuelled, whichever occurssooner.

o Engine oil level.o Coolant level.o Power steering fluid level.o Brake fluid level.o Windscreen washer fluid level.o Battery condition.o Tyre condition and pressures.o Operation and cleanliness of all

lighting equipment.o Windscreen wiper and washer op-

eration.o Horn operation.o Warning light operation.o Adjustment and cleanliness of mir-

rors.o Seat and seat belt adjustment and

operation.o Fluid leakage.

The vehicle must not be driven if thedaily operating checks indicate thatany item of equipment related to thesafety or roadworthiness of the ve-hicle is not functioning correctly.

ENGINE OIL

G030A01FC-EAT

The correct engine oil level is of para-mount importance. An excessivelyhigh or low oil level may result inirreparable damage being sustainedby the engine. The engine oil levelmust be checked on a daily basis,whenever the vehicle is refuelled orbefore starting a long trip, whicheveroccurs sooner.In addition, it is imperative that onlyan approved grade and specificationof oil is used to avoid the possibility ofserious engine damage and prema-ture wear. The use of "budget price"oil is a false economy that must beavoided if the maximum reliability anduseful life is to be obtained from thevehicle.

G030B01HP

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The oil viscosity should be selectedaccording to the operating environ-ment of the engine by means of thetable shown above. The engine oilrecommendations are complete inthemselves and the use of addi-tives is neither required nor recom-mended. The use of engine oil addi-tives may result in invalidation ofthe vehicle warranty.

NOTE:The use of a 5W-20 multi grade oil isnot recommended for sustained highspeed use.

2. Diesel Engine(1) Select engine oil of the proper SAE

viscosity number according to theatmospheric temperature.Recommended viscosity is givenin the following illustration.

NOTE:SAE 5W-30 oil should be used onlyin areas where extremely cold tem-peratures of 50°F(10°C) or below areexperienced.

If the atmospheric temperatures are32°F (0°C) or below, SAE #30 oilmust not be used. This oil shouldbe used only in areas where theatmospheric temperatures are 32°F(0°C) or above.

(2) The engine oil quality should meet

G030B03HP

the following classification:

API: CF-4 or ABOVEACEA: B4 or ABOVE

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SG030C2-E

Engine Oil Level

The engine oil level should be checkedwith the engine at normal operatingtemperature and the vehicle parkedupon level ground.

Prior to checking the level, the vehicleshould be allowed to stand for severalminutes after the engine has beenswitched off to allow the oil to drainback to the sump.Withdraw the dipstick and wipe it witha clean rag. Replace the dipstick fullyand withdraw again when the oil levelmay be read from the stick. Normaloil level is indicated when the oil ispresent between the two marks onthe stick. It is not necessary to add oilif the level is above the lower markand in any case, oil must not beadded to the degree that the levelexceeds the upper mark. Replace thedipstick fully after checking the level.

HPG030C2-E

ENGINE OIL REPLENISHMENT

If the indicated oil level is at or belowthe lower mark of the dipstick, oilshould be added until the level is at orbelow the upper mark.

HHP5002-E

Petrol Engine

Diesel Engine

G030C01HP

HHP5003

G030D01HP

Petrol Engine

Diesel Engine

! WARNING:Be very careful not to touch theradiator hose when checking theengine oil as it may be hot enoughto burn you.

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G350A01A-EAT

ENGINE OIL CONSUMPTIONFunction of engine oil

Engine oil has the primary function oflubricating and cooling the inside ofthe engine.

Engine oil consumption

It is normal that an engine shouldconsume some engine oil whilst nor-mal driving.The causes of oil consumption in anormal engine are as follows;

o Engine oil is used to lubricate pis-tons, piston rings and cylinders.A thin film of oil is left on thecylinder wall when a piston movesdownwards in the cylinder.High negative pressure generatedduring engine operation sucks someof this oil into the combustion cham-ber.This oil with some oil of the cylin-der wall is burned by the high tem-perature combustion gases duringthe combustion process.

o The engine oil consumption isstrongly effected by the viscosityand quality of oil, engine rpm anddriving condition etc.More engine oil may be consumedunder severe driving conditionssuch as high speeds, frequent ac-celeration and deceleration, com-pared to normal driving.

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To add oil to the engine, remove thefiller cap by rotating in an counter-clockwise direction and pour engineoil into the engine. Before checkingthe level again, allow several minutesfor the oil to drain into the sump.Replace the oil filler cap rotating it ina clockwise direction until tight.The quantity of oil required to raise thelevel from the minimum to maximumlevel is approximately 1 litre (PetrolEngine)/1.4 litres (Diesel Engine).

WARNING:Be very careful not to touch theradiator hose when adding the en-gine oil as it may be hot enough toburn you.

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The engine oil and filter must bechanged at the time or mileage intervalspecified in the maintenance sched-ule. If the vehicle is operated under

severe or adverse conditions, the oiland filter must be replaced more fre-quently.

To replace the oil and filter, proceed asfollows:

1. Ensure that the engine is at normaloperating temperature and park thevehicle on level ground with theparking brake securely applied andthe engine turned off.

2. Open the bonnet and remove theoil filler cap.

3. Prepare a suitable receptacle tocollect the displaced oil and re-move the drain plug from the sump.

4. When the oil has drained from thesump, replace the drain plug using anew washer ensuring that the plugis not over tightened.

Tightening torque : 3.5 ~ 4.5 kgf.m

5. Remove the oil filter by rotatingcounterclockwise, using a propri-etary oil filter removal tool if neces-sary. Note that the oil filter willcontain approximately 0.5 litres ofoil and this should be collected in asuitable receptacle.

6. Install a new oil filter havingsmeared the sealing ring with cleanoil and rotating clockwise until thefilter contacts the mounting andthen a further one half turn. Do notover-tighten.

Tightening torque:Petrol Engine - 1.2 ~ 1.6 kgf.mDiesel Engine - 2.3 ~ 2.5 kgf.m

7. Remove the engine oil level dipstick.8. Pour the specified quantity of the

recommended oil into the engineand replace the filler cap. Start the

CAUTION:The oil being drained from the en-gine will be hot. Care should beexercised to prevent scalding.

ENGINE OIL AND FILTERREPLACEMENT

G040A02HP-EAT

G040A01HP

Petrol Engine

Oil filterDrain plug

Oil filler cap

HHP5004

Diesel Engine Oil filler cap

Oil filterDrain plug

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engine and ensure that no oil leaksexist. Turn off the engine and aftera couple minutes, recheck the oillevel.

CAUTION:Slowly pour the recommended oilby using a funnel. Do not overfillnot to damage the engine.

WARNING:Prolonged and repeated contact withused engine oils may result in seri-ous skin disorders including der-matitis and cancer. Avoid contactwith skin as far as possible andalways wash thoroughly after anycontact. Keep used oils out of reachof children. It is illegal to pollutedrains, water courses and soil. Useonly authorized waste collectionfacilities including civic amenitysites and garages for the disposalof used oil and oil filters. If in doubt,contact the local authority for dis-posal instructions.

WARNING:Do not remove the radiator cap whenthe engine is hot, since the systemis pressurized and coolant may beejected from the radiator resultingin scalding.

SG050B1-E

Coolant recommendationsOnly ethylene glycol based coolantwith a corrosion inhibitor suited toaluminium alloy engine componentsshould be used in the cooling system.No further additives or inhibitorsshould be used. The coolant specificgravity should be checked as pre-scribed in the maintenance scheduleto ensure adequate frost and corro-sion protection. In addition, the en-gine coolant must be replaced at thespecified interval since the corrosioninhibitor properties deteriorate withtime.

ENGINE COOLANT CHECK-ING AND REPLACING

SG050A1-E

!

It is important to note that whilst anincrease in the concentration of antifreeze gives an increase in the levelof frost protection, a solution which isin excess of 65% anti freeze will resultin reduced frost protection and engineoverheating. Therefore the recom-mended concentration of 50% shouldnot be exceeded for general use.The use of methanol based anti freezecompounds may result in engine over-heating and will invalidate the vehiclewarranty.

NOTE:It is imperative that vehicles fittedwith an air conditioning systemhave a coolant concentration ofthe recommended strength at alltimes. The use of the air condition-ing system when the cooling sys-tem is filled with water only willresult in the heater matrix freezingand subsequently bursting.

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SG050C1-E

Coolant Level

The engine coolant level may beobserved through the side of the plas-tic coolant reservoir (expansion tank)when the engine is cold. If the level isbelow the "LOW" mark, add coolantof the correct concentration until thelevel is between the "LOW" and"FULL" marks. If the level falls belowthe "LOW" mark on a regular basisdespite being topped up, consult aHyundai dealer.

HPG050D2-E

To Change the Coolant

The coolant should be changed atthose intervals specified in the ve-hicle maintenance schedule in Sec-tion 5.

NOTE:Care should be taken to ensurethat coolant is not allowed to spillonto the paintwork since the fin-ish may become damaged. If cool-ant spillage occurs, the affectedarea should be rinsed thoroughlywith water.

1. Park the vehicle on level groundand ensure that the parking brakeis firmly applied, and the engineallowed to cool.Do not attempt this operation whilstthe engine is hot since burning orscalding may result.

2. Prepare a suitable receptacle tocollect the displaced coolant andposition this under the radiator draintap.

NOTE: Petrol Engine Only

Before adding the coolant to theradiator, unscrew the bolts on theengine cover, remove the enginecover and unscrew the flange boltfor fitting water outlet to escape theexcess pressure. And if the coolantoverflows from the hole whilst add-ing the coolant, screw the bolt andcontinue to add the coolant.

HHP5005-E

G050D02HP

Petrol Engine only

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3. With the heater temperature controlset to the "HOT" position, removethe radiator cap and open the radia-tor drain tap.

4. When the engine coolant has drainedcompletely, close the drain tap en-suring that this is not over tight-ened.

5. Prepare a suitable quantity of newengine coolant (refer to section 9)and pour this into the radiator.

6. Start the engine with the radiatorcap still removed and continue toadd coolant as the level decreasesas air is expelled from the system.When the level remains constant,replace the radiator cap and replen-ish the coolant reservoir.

7. When the engine is hot, check toensure that no coolant leaks arepresent.

G050D01HP-D

HHP5006-E

HHP5008

Petrol Engine

Diesel Engine

! WARNING:The cooling fan is controlled byengine coolant temperature and maysometimes operate even when theengine is not running. Use extremecaution when working near theblades of the cooling fan so thatyou are not injured by a rotating fanblade. As the engine coolant tem-perature decreases, the fan will au-tomatically shut off. This is a nor-mal condition.

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!Your engine was originally equippedwith platinum-tipped spark plugs.Platinum-tipped spark plugs will lastlonger than conventional type sparkplugs and can be identified by bluelines on the ceramic shell.

NOTE:Do not clean or regap platinum-tipped spark plugs.

G060B03L-EAT

Replacing the Spark Plugs

The spark plugs should be changedat the intervals specified in the ve-hicle maintenance schedule in Sec-tion 5 or whenever engine perfor-mance indicates they should bechanged. Symptoms that suggest poorspark plug performance include en-gine misfiring under load, loss of fueleconomy, poor acceleration, etc.When spark plugs are replaced, al-ways use spark plugs recommendedby Hyundai. The use of other sparkplugs can result in loss of perfor-mance, radio interference or enginedamage.

NOTE:o When replacing the spark plug,

Genuine Hyundai ReplacementParts are recommended.

Recommended Spark Plugs:

o It is recommended that sparkplugs be changed by anauthorised Hyundai dealer.

WARNING:It is recommended that the enginebe cool or cold when changing thespark plugs. If the engine is hot,you could burn yourself on theinsulated connector, the spark plugor the engine itself.

Type

RC10PYPB4 (CHAMPION)

PFR5N-11 (NGK)

Remark

Unleaded

SPARK PLUGS

G060A02L-AAT

(For Petrol Engine)

G060A01L

0.039 ~ 0.043 in.(1.0 ~ 1.1mm)

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!G070A03Y-AAT

CHANGING THE AIR CLEANERFILTER CAUTION:

o Operating your vehicle withouta proper air cleaner filter in placecan result in excessive enginewear.

o When removing the air cleanerfilter, be careful that dust or dirtdoes not enter the air intake.These may result in damage tothe air cleaner filter.

The replacement of air cleaner filter isperformed in the following manner.

1. Unsnap the clips around the cover.2. When this is done, the cover can

be lifted off, the old filter removedand the new filter put in its place.

Genuine Hyundai replacement partsare recommended.

HHP5013-E

The wiper blades should be carefullyinspected from time to time andcleaned to remove accumulations ofroad film or other debris.To clean the wiper blades and arms,use a clean sponge or cloth with amild soap or detergent and water.If the wipers continue to streak orsmear the glass, replace them withgenuine Hyundai replacement partsor their equivalent.

WINDSCREEN WIPERBLADES

ZG080A2-E

HHP5045-E

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CAUTION:o Do not operate the wipers on dry

glass. This can result in morerapid wear of the wiper bladesand may scratch the glass.

o Keep the blade rubber out ofcontact with petroleum productssuch as engine oil, petrol, etc.

!G080B01HR-EAT

Replacing the Wiper Blades

To replace the wiper blades, raise thewiper to the vertical.

To remove the wiper blade

1. Push down the wiper blade with thelocking clip (1) pressed to detach itfrom the wiper arm.

2. Raise the wiper blade lightly andpull up it.

HHR5048

HHR5049

(1)

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The level of windscreen washer fluidavailable should be checked on a dailybasis. The level of fluid will be visiblethrough the side of the reservoir. Whenthe fluid is to be replenished, only aproprietary screen wash additive shouldbe used and in the concentration rec-ommended by the manufacturer. Thewindscreen washer reservoir has atotal capacity of 4.5 litres.

HHP5017-E

To install the wiper blade

1. Put a new wiper blade onto thewiper arm and lower the wiper bladeat the level of the wiper arm asshown in the drawing.

HHR5050 2. Pull up the wiper blade until youhear an audible "click" to engage inthe end of the wiper arm.

NOTE:Do not allow the wiper arm to fallagainst the windscreen.

HHR5051

WINDSCREEN WASHER RES-ERVOIR REPLENISHMENT

HPG090A1-E

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!! CAUTION:Engine coolant anti freeze must notbe used in the windscreen washersystem since damage to thepaintwork may result.Undiluted windscreen washer addi-tive must not be allowed to comeinto contact with the paintwork. Ifspillage occurs, flush the affectedarea immediately with water. Donot operate the windscreen washerfor more than 15 seconds continu-ously or when the reservoir isempty since damage to the washerpump will result.

The transmission lubricant should bechecked and/or changed at intervalsspecified in the maintenance sched-ule.

Recommended LubricantUse only HYUNDAI GENUINEPARTS MTF 75W/90 (API GL-4).

CAUTION:The transmission lubricant levelshould only be checked when theengine is cold to prelude the pos-sibility of personal injury by con-tact with hot components.

1. To check the transmission lubricantlevel, the vehicle should be placedon level ground and the level plugremoved with a suitable spanner.

2. If the level is correct, lubricantshould begin to drip from the plugorifice. In this case the plug shouldbe replaced.If the level is incorrect, lubricantshould be added until it begins todrip from the plug orifice at whichtime the plug should be replaced.

MANUAL TRANSMISSIONLUBRICANT

G100A01HP-EAT

Drain plugHHP5010

Filler plug

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To Check the Transmission OilLevel

Park the car on level ground with theengine off.

1. Using a wrench of the correct size,loosen the oil filler bolt turning itcounterclockwise and remove itwith your fingers.

2. Use your finger to feel inside thehole. The oil level should be at itsbottom edge. If it is not, check forleaks before adding oil. To refillthe transmission or bring the oillevel up, add oil slowly until itreaches the proper level. Do notoverfill.

3. Replace the bolt and washer, screwit in with your fingers and thentighten securely with the wrench.

G100B01L

AUTOMATIC TRANSMIS-SION LUBRICANT

G110A04HP-EAT

Transmission lubricant should bechanged at those intervals specifiedin the vehicle maintenance schedulein Section 5.

NOTE:Basically automatic transmissionfluid is red color. As driving dis-tance increases, the fluid colorturns darkish red gradually. It isnormal condition and you shouldnot use fluid color as a criterionfor replacing the transmissionfluid.You must replace the automatictransmission fluid in accordancewith intervals specified in the ve-hicle maintenances schedule insection 5.

Recommended LubricantUse only MOBIL DEXRON-II. Dam-age caused by a nonspecified fluid isnot covered by your new vehicle lim-ited warranty.

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Transmission Fluid CapacityThe fluid capacity of the automatictransmission is 10.5 litres (Petrol En-gine)/ 11.8 litres (Diesel Engine).

To Check the Transmission FluidLevel

2. Remove the transmission dipstick,wipe it clean, reinsert the dipstickas far as it will go, then remove itagain. Now check the fluid level onthe dipstick. It should be in the"HOT" range on the dipstick.

CAUTION:The transmission fluid level shouldbe checked when the engine is atnormal operating temperature. Thismeans that the engine, radiator,exhaust system etc., are very hotso you should exercise great carenot to burn yourself during thisprocedure. Park the car on level ground with the

parking brake engaged. When thetransmission fluid level is checked,the transmission fluid should be atnormal operating temperature and theengine idling.Whilst the engine is idling, apply thebrakes and move the gear selectorlevel from "P" to each of its otherpositions — "R", "N", "D", "2", "L" —and then return to "N" or "P". With theengine still idling:

1. Open the bonnet, being careful tokeep hands and clothing clear ofany moving parts.

HHP3018-E

HHP5009-E

G110D01HP

Petrol Engine

Diesel Engine

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3. If the transmission fluid level is low,use a funnel to add transmissionfluid through the dipstick tube untilthe level reaches the "HOT" range.Do not overfill.

WARNING (Diesel only):Never work on injection system withengine running or within 30 sec-onds after shutting off engine. Highpressure pump, rail, injectors andhigh pressure pipes are subject tohigh pressure even after the enginestopped. The fuel jet produced byfuel leaks may cause serious injury,if it touch the body. People usingpacemakers should not move than30cm closer to the ECU or wiringharness within the engine roomwhilst engine is running, since thehigh currents in the Common Railsystem produce considerable mag-netic fields.

WARNING:The electric engine cooling fan au-tomatically switches on and off ac-cording to engine temperature. Becareful to keep away from the fanduring this check as it may switchon at any time.

NOTE:Only lint free cloth should be usedfor wiping the dipstick. The pres-ence of lint within the transmis-sion may cause problems with thenormal function of the transmis-sion.

CAUTION:Correct operation of the brakingsystem is essential to the safe op-eration of the vehicle and there-fore, any maintenance operationsother than those listed belowshould be entrusted to a Hyundaidealer.

SG120C2-E

Brake Fluid Recommendations

Only brake fluid conforming to DOT 3or DOT 4 specifications or highermay be used in the braking system.Care should be taken to observe theinstructions and precautions printedupon the container.

Fluid level should be within "HOT" range

G110D04HP

BRAKE SYSTEM CHECKING

SG120A1-E

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!SG120D1-E

Brake Fluid Level

The fluid level in the brake fluid reser-voir should be checked periodically.The level should be between the "MIN"and "MAX" marks on the side of thereservoir. If the level is at or belowthe "MIN" mark, fluid should be addedhaving carefully cleaned the area sur-rounding the reservoir cap to ensurethat dirt is not allowed to enter thesystem. It should be borne in mindthat the brake fluid level will decreaseslightly as the friction linings of thepads and shoes become worn andthat this is a normal condition.

WARNING:Brake fluid is hygroscopic andshould never be stored in an un-sealed container. The presence ofwater in the braking system willcause vapour locks and increasethe possibility of brake fade alongwith promoting corrosion withinthe braking system. The brake fluidmust be changed at the specifiedtime or mileage interval to ensurecontinued safe operation of thesystem. Brake fluid will cause rapidand serious damage to paintwork.If accidental spillage occurs, theaffected area must be rinsed withwater immediately. Do not allowbrake fluid to come into contactwith the eyes or to be ingestedand ensure that fluid is safelystored away form the reach of chil-dren.

The clutch fluid level in the mastercylinder should be checked when per-forming other under bonnet checks.The system should be checked forleakage at the same time.Ensure that the clutch fluid level isalways between the "MAX" and "MIN"level markings on the fluid reservoir.Fill as required. Fluid loss indicates aleak in the clutch system which shouldbe inspected and repaired immedi-ately.

HHP5015-E

CHECKING THE CLUTCHFLUID

SG130A1-C

To Check the Clutch Fluid

HHP5016-E

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SG130B2-E

Adding Fluid

Recommended brake fluid conform-ing to DOT 3 or DOT 4 should beused. The reservoir cap must be fullytightened to avoid contamination fromforeign matter or moisture.

CAUTION:Brake fluid is hygroscopic andshould never be stored in an un-sealed container. Do not allowpetroleum base fluid to contami-nate the brake fluid since damageto the rubber seals of the systemmay result.

WARNING:Brake fluid will cause rapid andserious damage to paintwork. Ifaccidental spillage occurs, the af-fected area must be rinsed withwater immediately. Do not allowbrake fluid to come into contactwith the eyes or to be ingestedand ensure that fluid is safelystored away form the reach of chil-dren.

SG140C2-E

Checking the Refrigerant

1. Start the engine and run at idle forseveral minutes with the refrigera-tion system running at the coldestsetting.

2. If the air coming out of the in-dashvents is not cold, have the air con-ditioning system inspected by yourHyundai dealer.

CAUTION:Running the air conditioning sys-tem for extended periods of timewith a low refrigerant level maydamage the compressor.

!

AIR CONDITIONING SYSTEMMAINTENANCE

SG140A1-E

Condenser

Ensure that the condenser is periodi-cally inspected and that accumula-tions of dirt, dead insects and leavesetc, are removed to ensure that theefficiency of the system is not im-paired. Care must be exercised toensure that the condenser fins arenot damaged during cleaning.

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SG140D1-E

Off Season Maintenance

The air conditioning must be run forten minutes or so weekly during peri-ods when the system would not nor-mally be used to ensure that thecompressor and seals are lubricated.If this precaution is not observed thecompressor seals may become stuckto the compressor shaft and dam-aged when the system is next usedresulting in a loss of refrigerant anddamage to the compressor.

HPG140B1-E

Compressor Drive BeltThe air conditioning compressor drivebelt should be checked to ensurefreedom from damage or excessivewear and correct tension. The belttension is correct when the belt de-flects by about 0.3 inches (8 mm)when a force of 98 N is applied to thebelt halfway between the compressorand crankshaft pulleys. Adjustment ofthe belt should be entrusted to aHyundai dealer.

NOTE:The compressor drive belt tensionfor diesel engine is adjusted auto-matically.

G140D03HP

Diesel EngineGenerator pulley Water pump pulley

COMP. pulley

Idler pulley

Auto tensioner

Crankshaft pulley

G140D01HPCrankshaft pulley

Petrol Engine

COMP.pulley

Tension pulley

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To check the steering wheel free-play,stop the car with the wheels pointedstraight ahead and gently move thesteering wheel back and forth. Usevery light finger pressure and be sen-sitive to changes in resistance thatmark the limits of the free-play.If the free-play is greater than speci-fied, have it inspected by your Hyundaidealer and adjusted or repaired ifnecessary.

YG170A1-E

Clutch Pedal

The clutch pedal freeplay must liewithin the limits shown. Incorrect free-play can result in premature wear ofthe clutch linings and release bearing.Excessive free-play can result in gearselection difficulties.If the free-play is incorrect, the clutchcable should be adjusted by a Hyundaidealer.

G170A01A-GAT

Brake Pedal

With the engine off, press down on thebrake pedal several times to reducethe vacuum in the brake booster.Then, using your hand, press downslowly on the brake pedal until youfeel a change in resistance. This isthe brake pedal free-play. The free-play should be within the limits speci-fied in the illustration. If it is not, haveit inspected by your Hyundai dealerand adjusted or repaired if necessary.

CHECKING THE FREE-PLAY

YG180A1-E

Steering Wheel

Maximum1.18 in(30 mm)

HHP5044

0.24 ~ 0.51 in.(6 ~ 13 mm)

G160A01HP

0.12 ~ 0.31 in.(3 ~ 8 mm)

G160A01HP

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You need a helper to check the brakepedal clearance. With the engine run-ning, have your helper press down onthe brake pedal several times andthen hold it down with a force of about490 N (50 Kg, 110 lbs). The brakepedal clearance is the distance fromthe top surface of the brake pedal tothe asphalt sheeting under the floormat.If the brake pedal clearance is notwithin the limits specified in the illus-tration, have it inspected by yourHyundai dealer and adjusted or re-paired if necessary.

HPG190A1-E

ADJUSTING DRIVE BELTS

If a belt is loose, adjust it by:

CHECKING BRAKE PEDALCLEARANCE

2.95 in. (75 mm)

G180A01L

G190D01HP

Petrol Engine

Idler pulley

Power steering pulley

Crankshaft pulley

Generatorpulley

Tension pulley

Tension pulley

Tensionpulley

COMP. pulley

HHP5049

Diesel EngineGenerator pulley

Tension pulley

COMP. pulley

Powersteeringpulley

Idler pulley

Auto tensioner

Crankshaft pulley

Water pump pulley

G180A01A-GAT

CHECKING ENGINE DRIVEBELTS

YG200A1-E

1. With the engine turned off, checkthe belts for cracks, fraying, orexcessive wear. Replace the belt ifit is in poor condition.

2. With your thumb (with a forceapprox. 10 kg) press on each beltmidway between the pulleys. Eachbelt should deflect no more thanthe amount shown in figure.

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!!

1. Loosen the adusting bolts justenough so that the componentscan be moved.

2. Whilst pulling outward on the pry baror screwdriver, test the belt deflec-tion with your thumb.

3. After tightening the adjusting bolts,be sure to recheck the belt tension.Overtightening drive belts cancause excessive wear and failurein driven components and belts.

WARNING:The drive belt should be checkedwhen the engine is cool or cold toavoid burning yourself on hot en-gine.

The fusible link prevents damage tothe wiring harness in the event of anelectrical system malfunction. Failureof a fusible link is indicative of aserious overload condition havingoccurred and therefore the electricalsystem should be checked by aHyundai dealer before a replacementlink is fitted.

WARNING:Under no circumstances should afusible link be replaced with any-thing other than a new link of thesame rating. The use of higherrated links or other means of con-necting the circuit will create apotential fire hazard.

FUSIBLE LINKS

DG200A1-E

G200A01HP-E

Bad Good

G200A02HP-E

Bad Good

6 OWNER MAINTENANCE

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!

DG200B1-E

INDIVIDUAL CIRCUIT FUSES

The fuse box containing the individualcircuit fuses is located on the lowerportion of the dashboard adjacent tothe bonnet release. The fuse boxcover is removed by pushing lightlyand then releasing the lid. A fuserating grid will be found on the re-verse side of the cover. In the eventof fuse failure, the fuse should bereplaced with one of equivalent rat-ing. A fuse removal tool is providedwithin the fuse box to facilitate re-placement.

In the event of a replacement fusefailing shortly after installation a mal-function within the circuit protected bythat fuse is indicated. The circuitshould be checked by a Hyundaidealer at the first available opportu-nity.

WARNING:The use of replacement fuses hav-ing a higher rating than specifiedor other means of connecting thecircuit will create a potential firehazard.

NOTE:See page 6-36 for the fuse paneldescriptions.

G200B01HP-E

HHP4002-EGood

G200B02L

Burned out

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! WARNING:Motor vehicle batteries containsulphuric acid which is corrosiveand poisonous. Hydrogen gas isemitted from the battery which isexplosive when combined withoxygen. The following precautionsmust be strictly observed to avoidpersonal injury or damage to thevehicle.

o If battery electrolyte is spilled ontoskin or into eyes, the effected areamust be flushed with copiousamounts of water and medical as-sistance sought.

o If battery electrolyte is ingested,copious amounts of water or milkfollowed by an antacid (raw egg ormilk of magnesia) must be drunk.Vomiting should not be inducedand medical assistance must besought.

o Batteries must only be charged inwell ventilated areas from whichnaked lights or sources of sparksare excluded.

o Ensure that children, pets or otherunauthorized persons are kept awayfrom batteries.

o Do not allow anything to bridge thepositive (+) and negative (-) termi-nals of the battery.

o Never invert the battery.

The battery fitted during production isof the "Maintenance Free" type.

BATTERY MAINTENANCE

DG210A2-E

HHP5020-E

! WARNING:Always read the followinginstructions carefully whenhandling a battery.Keep lighted cigarettes andall other flames or sparksaway from the battery.Hydrogen, which is a highlycombustible gas, is alwayspresent in battery cells andmay explode if ignited.Keep batteries out of thereach of children becausebatteries contain highly cor-rosive SULFURIC ACID. Donot allow battery acid tocontact your skin, eyes,clothing or paint finish.

6 OWNER MAINTENANCE

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! WARNING:The cooling fan is controlled byengine coolant temperature and maysometimes operate even when theengine is not running. Do not touchthe radiator fan until it is completelystopped.As the coolant temperature de-creases the fan will automaticallyshut off. This is a normal condi-tion.

Checking Engine Cooling Fan

The engine cooling fan should auto-matically come on if the engine cool-ant temperature is high.

Checking Condenser CoolingFan

The condenser cooling fan (in front ofthe condenser) should come on auto-matically whenever the air conditioneris in operation.

If any electrolyte gets intoyour eyes, flush your eyeswith clean water for at least15 minutes and get imme-diate medical attention. Ifpossible, continue to applywater with a sponge orcloth until medical atten-tion is received.If electrolyte gets on yourskin, thoroughly wash thecontacted area.If you feel a pain or a burn-ing sensation, get medicalattention immediately.Wear eye protection whencharging or working near abattery.Always provide ventilationwhen working in an en-closed space.

o When lifting a plastic-cased bat-tery, excessive pressure on thecase may cause battery acid toleak, resulting in personal injury.Lift with a battery carrier or withyour hands on opposite corners.

o Never attempt to charge the bat-tery when the battery cables areconnected.

o The electrical ignition systemworks with high voltage.Never touch these componentswith the engine running or theignition switched on.

CHECKING ELECTRICCOOLING FANS

YG210A1-E

6OWNER MAINTENANCE

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YG220A1-E

POWER STEERING HOSESIt is suggested that you check thepower steering hose connections forfluid leakage at those intervals speci-fied in the vehicle maintenance sched-ule in Section 5. The power steeringhoses should be replaced if there aresevere surface cracking, pulling, scuff-ing or worn spots. Deterioration of thehoses could cause premature failure.

NOTE:The power steering pump may benoisy when the engine is firststarted in the extreme cold (-4°F).This noise is not abnormal andwill stop as the engine warms up.If the power steering pump contin-ues to be noisy after the enginehas warmed up, have it inspectedby your Authorised Hyundai Dealer.

The power steering fluid level shouldbe checked regularly.To check the power steering fluid level,be sure the ignition is "OFF", thencheck to make certain that the powersteering fluid level is between the"MAX" and "MIN" level markings onthe fluid reservoir.

NOTE:Do not check whilst the engine isrunning. Do not start when powersteering fluid reservoir is empty.

Fluid Recommendation

Only automatic transmission fluidmeeting the specification of PSF-3 orATF DEXRON 2 should be used inthe power steering system.

POWER STEERING FLUIDLEVEL

G230A03A-EAT

Petrol Engine

G230A01HP-E

HHP5014-E

Diesel Engine

6 OWNER MAINTENANCE

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!

The fuel system should be bled toremove air as described in the illus-tration if the fuel supply is exhaustedduring travel, when the fuel filter isreplaced, or if the vehicle is not usedfor a long time.

1. Pump the hand prime pump withyour hand for one minute(about20~30 times).

2. Turn the ignition key to the "START"position and release it 2~3 timesshortly until the engine starts.

CAUTION:Do not hold the ignition key in the"START" position for more than15 seconds. Doing so may causethe engine and the injection pumpto damage.

G300B02HP-GAT

Removal Of Water From TheFuel Filter (For Diesel Engine)

If the fuel filter warning lamp illumi-nates during driving, it indicates thatwater has accumulated in the fuelfilter. If this occurs, remove the wateras described below.

1. Loosen the drain plug at the bot-tom of the fuel filter.

2. Tighten the drain plug when waterno longer comes out.

FUEL FILTER

G350B01HP-GAT

Bleeding The Fuel System(For Diesel Engine)

HHP5048-E HHP5047-E

6OWNER MAINTENANCE

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!!

3. Check to be sure that the warninglamp illuminates when the ignitionkey is turned to "ON", and that itgoes off when the engine is started.If in doubt, consult your nearestauthorised HYUNDAI dealer.

NOTE:It is recommended that water accu-mulated in the fuel filter should beremoved by an authorised Hyundaidealer.

WARNING:Be sure to carefully wipe away anywater drained out in this manner,because the fuel mixed in thewater might be ignited and resultin a fire.

Before attempting to replace a head-light bulb, be sure the switch is turnedto the "OFF" position.The next paragraph shows how toreach the headlight bulbs so theymay be changed. Be sure to replacethe burned-out bulb with one of thesame number and wattage rating.Ensure that the replacement bulb hasthe same cap configuration and watt-age as the original.See page 6-35 for the wattage descrip-tions.

CAUTION:Keep the lamps out of contact withpetroleum product, such as oil,petrol, etc.

REPLACING HEADLIGHTBULBS

G260A01HP-EAT G270A01B-EAT

Headlight Bulb

1. Allow the bulb to cool. Wear eyeprotection.

2. Open the engine bonnet.3. Always grasp the bulb by its plas-

tic base, avoid touching the glass.4. Using a spanner, remove the head-

light assembly mounting bolts.5. Disconnect the power cord from

the bulb base in the back of theheadlight.

G270A01HP

6. Turn the plastic cover counterclock-wise and remove it.

6 OWNER MAINTENANCE

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7. Disconnect the connector from thebulb base in the back of the head-light.

G270A02HP

8. Push the bulb spring to remove theheadlight bulb.

!WARNING:

The halogen bulb contains gasunder pressure and if impactedcould shatter, resulting in flyingfragments. Always wear eye pro-tection when servicing the bulb.Protect the bulb against abrasionsor scratches and against liquidswhen lighted. Turn the bulb ononly when installed in a headlight.Replace the headlight if damagedor cracked. Keep the bulb out ofthe reach of children and disposeof the used bulb with care.

G270A03HP

9. Remove the protective cap fromthe replacement bulb and installthe new bulb by matching the plas-tic base with the headlight hole.Reattach the bulb spring and re-connect the connector.

10.Use the protective cap and cartonto promptly dispose of the old bulb.

11.Check for proper headlight aim.

G270A03O

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And then, draw a parallel line at 1.50in. (38 mm) under the horizontal line incase of adjusting the low beam or at0.83 in. (21 mm) under the horizontalline in case of adjusting the high beam.

7. Adjust each cut-off line of the lowbeam to the parallel line with aphillips screwdriver - VERTICALAIMING.

8. Adjust each cut-off line of the lowbeam to the each vertical line witha phillips screwdriver - HORIZON-TAL AIMING.

Before performing aiming adjustment,make sure of the following.

HEADLIGHT AIMING AD-JUSTMENT

G290A01HP-EAT 1. Keep all tyres inflated to the correctpressure.

2. Place the vehicle on level groundand press the front bumper & rearbumper down several times. Placevehicle at a distance of 118.1 in.(3m) from the test wall.

3. See that the vehicle is unloaded(except for full levels of coolant,engine oil and fuel, and spare tyre,jack, and tools). Have the driver orequivalent weight placed in driver'sseat.

4. Clean the headlight lens and turn onthe headlight.

5. Open the bonnet.6. Draw the vertical line (through the

centre of each headlight) and thehorizontal line (through the centreof each headlight) on the aimingscreen.

(1) Horizontal line dimension from

<Low Beam>

<High Beam>

Horizontalaiming

Verticalaiming

G290B01HP

G290B02HP

Horizontalaiming

Verticalaiming

ground :Low Beam : 35.1 in.(894 mm)High Beam : 33 in. (839 mm)

(2) Distance between each verticalline :Low Beam : 51.8 in. (1,316 mm)High Beam : 42.4 in. (1,076 mm)

6 OWNER MAINTENANCE

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G290B01HP-EAT

Adjustment After Headlight As-sembly Replacement

If the vehicle has had front body repairand the headlight assembly has beenreplaced, the headlight aiming shouldbe checked using an aiming screen as

shown in the illustration. Turn on theheadlight switch (Low Beam or HighBeam Position).

1. Adjust headlights so that main axisof light is parallel to centre line ofthe body and is aligned with point"P" shown in the illustration.

2. Dotted lines in the illustration showthe centre of headlights.

"H"Horizontal centre line of headlightsfrom ground :Low Beam : 35.1 in. (894 mm)High Beam : 33 in. (839 mm)

"W"Distance between each headlightcentre :

Low Beam : 51.8 in. (1,316 mm)High Beam : 42.4n. (1,076 mm)

"L"Distance between the headlightsand the wall that the lights aretested against :Low Beam : 118.1 in. (3,000 mm)High Beam : 118.1in. (3,000 mm)

G290B02HP-E

G290B01HP-E

L

W

Cut-off line

Groundline

"P"

Horizontal lineVertical line 1.5 in.(38 mm)

0.55 in.(14 mm)

<Low Beam>

<High Beam>

H

H

L

W

Cut-off line

Groundline

"P"

Horizontal lineVertical

0.83 in.(21mm)

1.54 in.(39 mm)

H

H

line

6OWNER MAINTENANCE

35

Wattage

55/55

5

21

8

10

55

5

5

Part Name

Headlight (Low/High Beam)

Front position Light

Front Turn Signal Light

Map Light

Interior Light

Front Fog Light

Side Repeater Light

Front Door Edge Warning Light

Wattage

10

16

No.

9

10

11

12

Part Name

Luggage Compartment Light

High Mounted Rear Stop Light

Rear Combination Light

Stop/Tail Light

Turn Signal Light

Back-up Light

Rear Fog Light

License Plate Light

No.

1

2

3

4

5

6

7

8

BULB WATTAGES

G280A01HP

G280A02HP-EAT

21/5

21

16

21

5

6 OWNER MAINTENANCE

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NO.1

NO. 2

NO. 3

NO.4

NO.5

NO. 6

NO. 7

NO. 8

NO. 9

NO. 10

NO. 11

NO. 12

DESCRIPTION

G200C01HP-EAT

Engine Compartment (#1)

G200C01HP-E

NOTE:Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time ofprinting. When you inspect the fuse box on your vehicle, refer to the fuse box label.

AMPERAGES

100A

120A (DIESEL)

140A (PETROL)

50A

30A

-

-

20A

10A

15A

-

10A

10A

CIRCUIT PROTECTED

Glow Relay (COVEC-F/EGR), Air Heater Relay (Diesel Engine)

Engine Compartment Fuse & Relay Box #2,

Generator

Inner Panel Fuse Box (Fuse 1,2,3,4,5)

Engine Compartment Fuse & Relay Box #1 (Fuse 8,9)

Fuel Heater Control Module (COVEC-F/EGR)

Generator, Ignition Switch

-

-

Engine Control Relay (Diesel Engine), Main Control Relay

(Petrol Engine)

Horn Relay

Front Fog Lamp Relay

-

ECM (Diesel Engine), EGR Control Module

ECM (Diesel Engine)

FUSIBLE

LINK

FUSE

FUSE PANEL DESCRIPTION

Petrol Engine

Diesel Engine

6OWNER MAINTENANCE

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NOTE:Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time ofprinting. When you inspect the fuse box on your vehicle, refer to the fuse box label.

G200D01HP-EAT

Engine Compartment (#2)

G200C02HP

6 OWNER MAINTENANCE

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AMPERAGES

15A

15A

15A

-

10A

10A

-

15A

15A

15A

15A

10A

10A

10A

10A

10A

10A

15A

25A

20A

NO. 10

NO. 11

NO. 12

NO. 13

NO. 14

NO. 15

NO. 16

NO. 17

NO. 18

NO. 19

NO. 20

NO. 21

NO. 22

NO. 23

NO. 24

NO. 25

NO. 26

NO. 27

NO. 28

NO. 29

DESCRIPTION CIRCUIT PROTECTED

Fuel Heater and Sensor(Diesel Engine)

Headlamp(Low beam)

Headlamp(High beam)

-

A/C Compressor Relay, Triple Switch

TCI Fan Relay(COVEC-F/EGR)

-

-

ECM(Diesel Engine)

ECM(Diesel Engine)

ECM(Diesel Engine), Air Heater Relay(Diesel Engine), EGR Solenoid(Diesel Engine)

Illuminations, Combination Lamp

License Lamp, Combination Lamp

ABS Control Module, ABS Relay, EBD Relay

ECM(Diesel Engine), Headlamp Relay, Condenser Fan Relay

(Petrol/COVEC-F), EGR Solenoid(COVEC-F)

ABS Control Module

Cruise Control Module

Front Wiper and Washer

Power Seat Switch

Power Outlet Relay

FUSE

6OWNER MAINTENANCE

39

AMPERAGES

50A

30A

40A

40A

30A

40A

20A

-

20A

10A

15A

NO. 1

NO. 2

NO. 3

NO. 4

NO. 5

NO. 6

NO. 7

NO. 8

NO. 9

DESCRIPTION CIRCUIT PROTECTED

Power Connector(A,B), Engine Compartment Fuse and Relay #2

(Fuse 28,29), Inner Panel Fuse Box(Fuse 6,7,8, 9)

Start Relay, Ignition Switch

Condenser Fan Relay, Engine Compartment Fuse and Relay Box #2

(Fuse 14,15)

ABS Control Module

Power Window Relay

Tail Lamp Relay, Engine Compartment Fuse and Relay Box #2

(Fuse 11,12)

ABS Control Module

-

Fuel Pump Relay, ECM, Ignition Failure Sensor

A/CON, TCM, ETACM, Data Link Connector, Siren, Immobiliser

Control Module

Interior Lamp, Map Lamp, Audio, Instrument Cluster, Front Door Edge

Warning Lamp

FUSIBLE

LINK

NO. 30

NO. 31

6 OWNER MAINTENANCE

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NO.12345678910111213141516171819202122232425262728

AMPERAGES30A10A15A20A10A15A30A20A10A10A20A10A

--

10A10A

-10A10A10A10A10A10A

-10A15A15A10A

CIRCUIT PROTECTEDDefogger RelayHazard Relay, Hazard SwitchStop Lamp SwitchTOD, EST Control Module-Sunroof ControllerBlower RelayPower Door LocksRear Fog Lamp RelayAudio, Map LampCigar Lighter, Power Outlet relay, ACC SocketPower Outside Mirror Switch--A/C SwitchLeft/Right Outside Mirror & Defogger-TCM, ECM(COVEC-F), TCCS(TOD, EST), ImmobiliserBack-up Lamp Switch, Inside Rearview Mirror, Transmission Range SwitchHazard SwitchInstrument Cluster, ETACM, Vehicle Speed Sensor, DRL Control ModuleAirbagAirbag Indicator-Blower & A/C, ETACM, Defogger RelaySeat WarmerSunroof, Rear Wiper & Washer, Cruise Switch, Rear Intermittent Wiper RelayStart Relay, Theft-Alarm Relay

G200E01HP-EAT

Inner Panel

NOTE:Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time ofprinting. When you inspect the fuse box on your vehicle, refer to the fuse box label.

G200D01HP