2003 Hyundai Santa FE Owners Manual

D120A01A-AAT IF YOU LOSE YOUR KEYS

If you lose your keys, many Hyundai dealers can make you a new key if you have your key number. If you lock the keys inside your car and you cannot obtain a new key, many Hyundai dealers can use special tools to open the door for you.

D080D01O For emergency towing when no commercial tow vehicle is available, attach a tow cable, chain or strap to one of the tie-down hooks under the front of your car. Be very careful when attempting this procedure when the vehicle is on any unpaved surface to avoid damage to your vehicle. Nor should towing be attempted if the wheels, drive train, axles, steering or brakes are dam- aged. Before towing, be sure the transaxle is in neutral and the key is in "ACC" (with the engine off) or in the "ON" position (with the engine running). A driver must be in the towed car to steer it and operate the brakes.

4. CORROSION PREVENTION &

APPEARANCE CARE

Corrosion Protection ........................................................................4-2
To Help Prevent Corrosion ..............................................................4-2
Washing and Waxing .......................................................................4-3
Cleaning the Interior .........................................................................4-4

4- 2 CORROSION PREVENTION AND APPEARANCE CARE

E010A01A-AAT CORROSION PROTECTION

E010D01A-AAT Moisture Breeds Corrosion

E020B01A-AAT Keep Your Car Clean

Protecting Your Hyundai from Corrosion By using the most advanced design and con- struction practices to combat corrosion, Hyundai produces cars of the highest quality. However, this is only part of the job. To achieve the long-term corrosion resistance your Hyundai can deliver, the owner's cooperation and assistance is also required.

E010B01A-AAT Common Causes of Corrosion

The most common causes of corrosion on your car are:

o Road salt, dirt and moisture that is allowed to

accumulate underneath the car.

o Removal of paint or protective coatings by stones, gravel, abrasion or minor scrapes and dents which leave unprotected metal exposed to corrosion.

E010C01A-AAT High-Corrosion Areas

If you live in an area where your car is regularly exposed to corrosive materials, corrosion pro- tection is particularly important. Some of the common causes of accelerated corrosion are road salts, dust control chemicals, ocean air and industrial pollution.

Moisture creates the conditions in which corro- sion is most likely to occur. For example, cor- rosion is accelerated by high humidity, particu- larly when temperatures are just above freez- ing. In such conditions, the corrosive material is kept in contact with the car surfaces by mois- ture that is slow to evaporate. Mud is particularly corrosive because it is slow to dry and holds moisture in contact with the vehicle. Although the mud appears to be dry, it can still retain the moisture and promote corro- sion. High temperatures can also accelerate corro- sion of parts that are not properly ventilated so the moisture can be dispersed. For all these reasons, it is particularly important to keep your car clean and free of mud or accumulations of other materials. This applies not only to the visible surfaces but particularly to the underside of the car.

E020A01A-AAT TO HELP PREVENT CORROSION

You can help prevent corrosion from getting started by observing the following:

The best way to prevent corrosion is to keep your car clean and free of corrosive materials. Attention to the underside of the car is particu- larly important.

o If you live in a high-corrosion area — where road salts are used, near the ocean, areas with industrial pollution, acid rain, etc.—, you should take extra care to prevent corrosion. In winter, hose off the underside of your car at least once a month and be sure to clean the underside thoroughly when winter is over.

o When cleaning underneath the car, give particular attention to the components under the fenders and other areas that are hidden from view. Do a thorough job; just dampening the accumulated mud rather than washing it away will accelerate corrosion rather than prevent it. Water under high pressure and steam are particularly effective in removing accumulated mud and corrosive materials. o When cleaning lower door panels, rocker panels and frame members, be sure that drain holes are kept open so that moisture can escape and not be trapped inside to ac- celerate corrosion.

E020C01A-AAT Keep Your Garage Dry

Don't park your car in a damp, poorly ventilated garage. This creates a favorable environment for corrosion. This is particularly true if you wash your car in the garage or drive it into the garage when it is still wet or covered with snow, ice or mud. Even a heated garage can contrib- ute to corrosion unless it is well ventilated so moisture is dispersed.

E020D01A-AAT Keep Paint and Trim in Good Condition

Scratches or chips in the finish should be covered with "touch-up" paint as soon as pos- sible to reduce the possibility of corrosion. If bare metal is showing through, the attention of a qualified body and paint shop is recommended.

E020E01A-AAT Don't Neglect the Interior

Moisture can collect under the floor mats and carpeting to cause corrosion. Check under the mats periodically to be sure the carpeting is dry. Use particular care if you carry fertilizers, clean- ing materials or chemicals in the car. These should be carried only in proper contain- ers and any spills or leaks should be cleaned up, flushed with clear water and thoroughly dried.

CORROSION PREVENTION AND APPEARANCE CARE 4- 3

E030A01A-AAT WASHING AND WAXING Washing Your Hyundai

Never wash your car when the surface is hot from being in the sun. Always wash your car in the shade.

Wash your car frequently. Dirt is abrasive and can scratch the paint if it is not removed. Air pollution or acid rain may damage the paint and trim through chemical action if pollutants are allowed to remain in contact with the surface. If you live near the ocean or in an area where road salts or dust control chemicals are used, you should pay particular attention to the underside of the car. Start by rinsing the car to remove dust and loose dirt. In winter, or if you have driven through mud or muddy water, be sure to thor- oughly clean the underside as well. Use a hard direct stream of water to remove accumulations of mud or corrosive materials. Use a good quality car-washing solution and follow the manufacturer's directions on the package. These are available at your Hyundai dealer or auto parts outlet. Don't use strong household detergents, gasoline, strong solvents or abra- sive cleaning powders as these may damage the finish. Use a clean sponge or cloth, rinse it frequently and don't damage the finish by rubbing too hard. For stubborn spots, dampen them frequently and remove them a little at a time. To clean whitewall tires, use a stiff brush or soapy steel-wool scouring pad.

To clean plastic wheel covers, use a clean sponge or soft cloth and water.

To clean cast aluminum alloy wheels, use a mild soap or neutral detergent. Do not use abrasive cleaners. Protect the bare-metal surfaces by cleaning, polishing and waxing. Because alumi- num is subject to corrosion, be sure to give aluminum alloy wheels special attention in win- ter. If you drive on salted roads, clean the wheels thoroughly afterwards.

After washing, be sure to rinse thoroughly. If soapy water dries on the finish, streaking will result.

When the weather is warm and the humidity low, you may find it necessary to rinse each section immediately after washing to avoid streaking.

After rinsing, dry the car using a damp chamois or soft, absorbent cloth. The reason for drying the car is to remove water from the car so it will dry without water spots. Don't rub, this can damage the finish.

If you find any nicks or scratches in the paint, use touch-up paint to cover them to prevent corrosion. To protect the paintwork of the car against corrosion, you must clean your Hyundai (at least once a month). Give special attention to the removal of salt, mud and other sub- stances on the underside of the splashboards of the car. Make sure that the outlets and the

4- 4 CORROSION PREVENTION AND APPEARANCE CARE

underside of the doors are open. Paint damage can be caused by small accumulation of tar, industrial precipitation, tree resin, insects and bird droppings, when not removed immediately. If water alone is not strong enough to remove the accumulated dirt, use a mild car washing solu- tion. Be sure to rinse the surface after washing to remove the solution. Never allow the solution to dry on the painted surfaces.

E030B01A-AAT Spot Cleaning

Don't use gasoline, strong solvents or corro- sive cleaning agents. These can damage the finish of the car. To remove road tar, use turpentine on a clean, soft cloth. Be gentle. To remove dead insects or tree sap, use warm water and mild soap or car-washing solution. Soak the spot and rub gently. If the paint has lost its luster, use a commercial car-cleaning polish.

E030C01A-AAT Polishing and Waxing

Always wash and dry the car before polishing or waxing or using a combination cleaner and wax. Use a good quality commercial product and follow the manufacturer's directions on the container. Polish and wax the bright trim pieces as well as the paint.

E030D01A-AAT When to Wax Again

You should polish and wax the car again when water no longer beads on a clean surface but spreads out over a larger area.

E030E01A-AAT Maintaining Bumpers

Special precautions must be observed to pre- serve the appearance of the bumpers on your Hyundai. They are:

o Be careful not to spill battery electrolyte or hydraulic brake fluid on the bumpers. If you do, wash it off immediately with clear water. o Be gentle when cleaning the bumper sur- faces. They are made of soft plastic and the surface can be damaged if mistreated. Do not use abrasive cleaners. Use warm water and mild soap or car-washing solution.

o Do not expose the bumpers to high tem- peratures. For example, if you have your car repainted, do not leave the bumpers on the car if the car is going to be placed in a high- temperature paint booth.

E040A01A-AAT CLEANING THE INTERIOR To Clean the Vinyl Upholstery

To clean the vinyl upholstery, first remove loose dirt and dust with a vacuum cleaner. Then apply a solution of mild soap or detergent and water using a clean sponge or soft cloth. Allow this to stay on the surface to loosen the dirt, then wipe with a clean damp sponge or cloth. If all the dirt stains are not removed, repeat this procedure until the upholstery is clean. Do not use gaso- line, solvent, paint thinner or other strong clean- ers.

E040B01A-AAT To Clean the Leather Upholstery (If installed)

In the normal course of use, leather upholstered surfaces will, like any material, pick-up dust and dirt. This dust and dirt must be cleaned off or it may work into the surface of the leather, caus- ing damage.

Fine leather needs care, and should be cleaned when necessary. Washing leather thoroughly with soap and water will keep your leather lustrous, beautiful and ensure you have many years of wear. Take a piece of cheese cloth and using any mild soap and lukewarm water, work up a good lather. Thoroughly wash the leather. Wipe clean with a slightly damp cloth and dry with soft cloth.

CORROSION PREVENTION AND APPEARANCE CARE 4- 5

Do this as often as the leather becomes soiled.

E040D01A-AAT Cleaning the Seat Belts

During tanning operations, sufficient oils are incorporated through processing that none need be applied during the life of the leather. Oil applied to the finished surface will in no way help the leather and may do more harm than good. Varnishes and furniture polishes should never be used under any conditions.

To clean the seat belts, use a cloth or sponge with mild soap or detergent and warm water. Do not use strong detergents, dye, bleach or abra- sive materials on the seat belts as this may weaken the fabric. While cleaning the belts, inspect them for ex- cessive wear, cuts, fraying or other signs of damage and replace them if necessary.

E040C01A-AAT Cleaning the Carpets

E040E01A-AAT Cleaning the Windows

Use a foam-type carpet cleaner. Cleaners of this type are available in aerosol cans in liquid form or powder. Read the instructions and follow them exactly. Using a vacuum cleaner with the appropriate attachment, remove as much dirt from the carpets as possible. Apply the foam following the manufacturer's direc- tions, then rub in overlapping circles. Do not add water. These cleaners work best when the carpet is kept as dry as possible.

You may use any household window cleaner on the windows. However, when cleaning the in- side of the rear window be careful not to damage the rear window defroster wiring.

E050A01A-AAT Any Questions?

If you have any questions about the care of your car, consult your Hyundai dealer.

5. VEHICLE MAINTENANCE

REQUIREMENTS

Maintenance Intervals ......................................................................5-2
Scheduled Maintenance ...................................................................5-4
Maintenance under Severe Usage Conditions .................................5-6
Explanation of Scheduled Maintenance Items .................................5-7

5- 2 VEHICLE MAINTENANCE REQUIREMENTS

F010A01A-AAT MAINTENANCE INTERVALS Service Requirements

To ensure that you receive the greatest number of miles of satisfying operation from your Hyundai, certain maintenance procedures must be per- formed. Although careful design and engineer- ing have reduced these to a minimum, those that are required are of the utmost importance. It is your responsibility to have these mainte- nance procedures performed to comply with the terms of the warranties covering your new Hyundai. The Owner's Handbook supplied with your new vehicle provides further information about these warranties.

F010B01A-AAT Maintenance Requirements

The maintenance required for your Hyundai can be divided into three main areas:

o Specified scheduled procedures o General checks o Do-it-yourself maintenance

F010C01A-AAT Specified Scheduled Procedures

F010D02A-AAT General Checks

These are the procedures such as inspections, adjustments and replacements that are listed in the maintenance charts starting on page 5-4. These procedures must be performed at the intervals shown in the maintenance schedule to assure that your warranty remains in effect. Although it is strongly recommended that they be performed by the trained technicians at your Hyundai dealer, these procedures may be per- formed at any qualified service facility. It is suggested that genuine Hyundai service parts be used for any required repairs or re- placements. Other parts of equivalent quality such as engine oil, engine coolant, manual or auto transaxle oil, brake fluid and so on which are not supplied by Hyundai Motor Company or its distributor may be used without affecting your warranty coverage but you should always be sure these are equivalent to the quality of the original Hyundai parts. Your Owner's Hand- book provides further information about your warranty coverage.

These are the regular checks you should per- form when you drive your Hyundai or you fill the fuel tank. A list of these items will be found on page 6-5.

F010E01A-AAT Do-It-Yourself Maintenance

If you are mechanically inclined, own a few tools that are required and want to take the time to do so, you can inspect and service a number of items. For more information about doing it your- self, see Section 6.

F010F01A-AAT A Few Tips

o Whenever you have your Hyundai serviced, keep copies of the service records in your glovebox. This will help ensure that you can document that the required procedures have been performed to keep your warranties in effect. This is especially important when service is not performed by an authorized Hyundai dealer.

o If you choose to do your own maintenance and repairs, you may find it helpful to have an official Hyundai Shop Manual. A copy of this publication may be purchased at your Hyundai dealer's parts department.

F020A02Y-AAT SCHEDULED MAINTENANCE REQUIREMENTS

VEHICLE MAINTENANCE REQUIREMENTS 5- 3

o Inspection should be performed any time a malfunction is experienced or suspected. o Receipts for all emission control system services should be retained to demonstrate compliance with conditions of the emissions system warranty.

o After 120 months or 150,000 miles (240,000
km), continue to follow the prescribed main- tenance intervals.

o For severe usage maintenance require-

ments, see page 5-6 of this section.

5- 4 VEHICLE MAINTENANCE REQUIREMENTS

F030A01A-AAT SCHEDULED MAINTENANCE

The following maintenance services must be performed to ensure good emission control and performance. Keep receipts for all vehicle emission services to protect your warranty. Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.

F030B01O-AAT R :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.

No.

DESCRIPTION

KILOMETERS X 1000

MILES X 1000

MONTHS

7.5

12

15

24

12

22.5

36

18

30

48

24

37.5

45

52.5

60

30

72

36

84

42

60

96

48

67.5

75

82.5

90

97.5

105

112.5

120

127.5

135

142.5

150

108

120

132

144

156

168

180

192

204

216

228

240

54

60

66

72

78

84

90

96

102

108

114

120

EMISSION CONTROL ITEMS

ENGINE OIL AND FILTER

FUEL FILTER

FUEL LINES, FUEL HOSES AND CONNECTIONS

VACUUM HOSE

CRANKCASE VENTILATION HOSE

VAPOR HOSE AND FUEL FILLER CAP

AIR CLEANER FILTER

SPARK PLUGS (PLATINUM COATED)

VEHICLE MAINTENANCE REQUIREMENTS 5- 5

F030C04O-AAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary

No.

DESCRIPTION

MILES X 1000
KILOMETERS X 1000
MONTHS

GENERAL ITEMS DRIVE BELT

2.4 DOHC (ALT, W/PUMP) 2.7 V6 / 3.5 V6 ( ALT, P/STR'G, A/CON)

COOLANT TIMING BELT MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID AND FILTER BRAKE FLUID BRAKE HOSES AND LINES REAR BRAKE DRUMS/LININGS, PARKING BRAKE BRAKE PADS, CALIPERS AND ROTORS EXHAUST PIPE AND MUFFLER SUSPENSION MOUNTING BOLTS STEERING GEAR BOX, LINKAGE & BOOTS / LOWER ARM BALL JOINT POWER STEERING PUMP BELT AND HOSES DRIVESHAFTS AND BOOTS AIR CONDITIONING REFRIGERANT TRANSFER CASE OIL (4WD) REAR AXLE OIL (4WD) PROPELLAR SHAFT CLEAN, BOLT RETIGHTEN (4WD)

10
11
12

13
14
15
16
17
18

7.5
12

15
24
12

22.5
36
18

30
48
24

37.5
60
30

45
72
36

52.5
84
42

60
96
48

R*¹

67.5
108
54

75
120
60

82.5
132
66

90
144
72

97.5
156
78

105
168
84

112.5
180
90

See Note *2
See Note *3

120
192
96

R*¹

127.5
204
102

135
216
108

142.5
228
114

150
240
120

Note : *1. For california, this maintenance is recommended, but not required. *2. Inspect every 25,000 miles (40,000 km)and replace every 62,000 miles (100,000 km) *3. With LSD- Inspect every 25,000 miles (40,000 km) and replace every 50,000 miles (80,000 km)

Without LSD- lnspect every 25,000 miles (40,000 km)

5- 6 VEHICLE MAINTENANCE REQUIREMENTS

F040A02O-AAT MAINTENANCE UNDER SEVERE USAGE CONDITIONS

The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals.

R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary

MAINTENANCE ITEM

MAINTENANCE

OPERATION

MAINTENANCE

INTERVALS

DRIVING

CONDITION

ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS BRAKE PADS, CALIPERS AND ROTORS REAR BRAKE DRUMS/LININGS/PADS, PARKING BRAKE STEERING GEAR BOX, LINKAGE & BOOTS/ LOWER ARM BALL JOINT DRIVESHAFTS AND BOOTS MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID AND FILTER TRANSFER CASE OIL (4WD) *1

REAR AXLE OIL (4WD) *1

With LSD Without LSD

EVERY 3,000 MILES (4,800 KM) OR 3 MONTHS MORE FREQUENTLY MORE FREQUENTLY MORE FREQUENTLY MORE FREQUENTLY

MORE FREQUENTLY

A, B, C, F, H C, E B, H C, D, G, H C, D, G, H

C, D, E, F, G

EVERY 7,500 MILES (12,000 KM) OR 6 MONTHS EVERY 60,000 MILES (96,000 KM) EVERY 30,000 MILES (48,000 KM) EVERY 25,000 MILES (40,000 KM) EVERY 25,000 MILES (40,000 KM) EVERY 50,000 MILES (80,000 KM)

C, E, F A, C, D, E, F, G, H, I, J A, C, E, F, G, H, I C, E, G, I

C, E, G, I

SEVERE DRIVING CONDITIONS A - Repeated short distance driving B - Extensive idling C - Driving in dusty, rough roads D - Driving in areas using salt or other corrosive materials or in

very cold weather

E - Driving in sandy areas *1. Transfer case Oil and Rear Axle Oil should be changed anytime they have been submerged in water.

F - More than 50% driving in heavy city traffic during hot weather

above 90°F (32°C)

G - Driving in mountainous areas H - Towing a trailer J - Driving over 100 mph

- Driving as a patrol car, taxi, other commercial use and vehicle towing

F060A01A-AAT EXPLANATION OF SCHEDULED MAIN- TENANCE ITEMS

F060M01A-AAT o Engine Oil and Filter

The engine oil and filter should be changed at the intervals specified in the maintenance sched- ule. If the car is being driven in severe condi- tions, more frequent oil and filter changes are required.

F060C01A-AAT o Fuel Filter

A clogged filter can limit the speed at which the vehicle may be driven, damage the emission system and cause hard starting. If an exces- sive amount of foreign matter accumulates in the fuel tank, the filter may require replacement more frequently. After installing a new filter, run the engine for several minutes, and check for leaks at the connections. Fuel filters should be installed by trained technicians.

F060B01A-AAT o Drive Belts

Inspect all drive belts for evidence of cuts, cracks, excessive wear or oil saturation and replace if necessary. Drive belts should be checked periodically for proper tension and adjusted as necessary.

VEHICLE MAINTENANCE REQUIREMENTS 5- 7

F060D01A-AAT o Fuel Lines, Fuel Hoses and Connec-

F060G01A-AAT o Vapor Hose and Fuel Filler Cap

tions

Check the fuel lines, fuel hoses and connec- tions for leakage and damage. Have a trained technician replace any damaged or leaking parts immediately.

The vapor hose and fuel filler cap should be inspected at those intervals specified in the maintenance schedule. Make sure that a new vapor hose or fuel filler cap is correctly re- placed.

F060F01A-AAT o Vacuum, Crankcase

Ventilation Hoses

Inspect the surface of hoses for evidence of heat and/or mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions, and excessive swelling indicate deterioration. Particular attention should be paid to examine those hose surfaces nearest to high heat sources, such as the exhaust manifold. Inspect the hose routing to assure that the hoses do not come in contact with any heat source, sharp edges or moving component which might cause heat damage or mechanical wear. Inspect all hose connections, such as clamps and couplings, to make sure they are secure, and that no leaks are present. Hoses should be replaced immediately if there is any evidence of deterioration or damage.

F060H01A-AAT o Air cleaner filter

A Genuine Hyundai air cleaner filter is recom- mended when the filter is replaced.

F060J01A-AAT o Spark plugs

Make sure to install new spark plugs of the correct heat range.

F060E01A-AAT o Timing belt

Inspect all parts related to the timing belt for damage and deformation. Replace any dam- aged parts immediately.

F070C01A-AAT o Coolant

The coolant should be changed at the intervals specified in the maintenance schedule.

5- 8 VEHICLE MAINTENANCE REQUIREMENTS

F070D01A-AAT o Manual transaxle oil

F070G02A-AAT o Brake Fluid

F070K01A-AAT o Exhaust Pipe and Muffler

Inspect the manual transaxle oil according to the maintenance schedule.

NOTE: If the oil level is low, check for possible leaks before adding oil. Do not overfill.

F070E03A-AAT o Automatic Transaxle Fluid and Filter

The fluid level should be in the "HOT" range of the dipstick, after the engine and transaxle are at normal operating temperature. Check the automatic transaxle fluid level with the engine running and the transaxle in neutral, with the parking brake properly applied. Use GENUINE HYUNDAI ATF or DIAMOND ATF SP-III or SK ATF SP-III when adding or changing fluid.

F070F01A-AAT o Brake Hoses and Lines

Visually check for proper installation, chafing, cracks, deterioration and any leakage. Replace any deteriorated or damaged parts immedi- ately.

Check brake fluid level in the brake fluid reser- voir. The level should be between "MIN" and "MAX" marks on the side of the reservoir. Use only hydraulic brake fluid conforming to DOT 3
or DOT 4.

Visually inspect the exhaust pipes, muffler and hangers for cracks, deterioration, or damage. Start the engine and listen carefully for any exhaust gas leakage. Tighten connections or replace parts as necessary.

F070H01A-AAT o Rear Brake Drums and Linings/

Parking Brake

Check the rear brake drums and linings for scoring, burning, leaking fluid, broken parts, and excessive wear. Inspect the parking brake system including the parking brake lever and cables. For detailed service procedures, refer to the Shop Manual.

F070J01A-AAT o Brake Pads, Calipers and Rotors

Check the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage.

F070L01A-AAT o Suspension Mounting Bolts

Check the suspension connections for loose- ness or damage. Retighten to the specified torque.

F070M01A-AAT o Steering Gear Box, Linkage & Boots/

Lower Arm Ball Joint

With the vehicle stopped and engine off, check for excessive free-play in the steering wheel. Check the linkage for bends or damage. Check the dust boots and ball joints for deterioration, cracks, or damage. Replace any damaged parts.

VEHICLE MAINTENANCE REQUIREMENTS 5- 9

F070N01A-AAT o Power Steering Pump, Belt and Hoses

Check the power steering pump and hoses for leakage and damage. Replace any damaged or leaking parts immediately. Inspect the power steering belt for evidence of cuts, cracks, ex- cessive wear, oiliness and proper tension. Replace or adjust it if necessary.

F070P01A-AAT o Driveshafts and Boots

Check the drive shafts, boots and clamps for cracks, deterioration, or damage. Replace any damaged parts and, if necessary, repack the grease.

F070Q01A-AAT o Air Conditioning Refrigerant

Check the air conditioning lines and connec- tions for leakage and damage. Check air con- ditioning performance according to the relevant shop manual if necessary.

6. Do-It-Yourself Maintenance

Engine Compartment .......................................................................6-2
General Checks ...............................................................................6-5
Checking the Engine Oil...................................................................6-6
Changing the Oil and Filter ...............................................................6-7
Checking and Changing the Engine Coolant....................................6-8
Spark Plugs ...................................................................................6-10
Changing the Air Cleaner Filter ......................................................6-12
Checking the Transaxle Oil (Manual) .............................................6-13
Checking the Transaxle Fluid (Automatic) .....................................6-13
Checking the Brakes .....................................................................6-15
Air Conditioning Care .....................................................................6-17
Checking Drive Belts .....................................................................6-19
Checking and Replacing Fuses .....................................................6-20
Checking the Battery .....................................................................6-21
Power Steering Fluid Level ............................................................6-22
Replacement of Light Bulbs ...........................................................6-24

6- 2 DO-IT-YOURSELF MAINTENANCE

G010A01O-AAT ENGINE COMPARTMENT (2.4 DOHC)

5 6

10

11

HSM241

1. Coolant reservoir cap 2. Brake & Clutch fluid reservoir 3. Air cleaner 4. Fuse and Relay box

5. Windshield washer fluid reservoir 6. Power steering fluid reservoir 7. Engine oil level dipstick 8. Radiator cap

9. Engine oil filler cap 10. Automatic transaxle fluid level dipstick

(Vehicle with Automatic Transaxle)

11. Battery

G010B01O-AAT ENGINE COMPARTMENT (2.7 V6)

DO-IT-YOURSELF MAINTENANCE 6- 3

5 6

10

11

G010B01O

1. Coolant reservoir cap 2. Brake & Clutch fluid reservoir 3. Air cleaner 4. Fuse and Relay box

5. Windshield washer fluid reservoir 6. Power steering fluid reservoir 7. Engine oil level dipstick 8. Radiator cap

9. Engine oil filler cap 10. Automatic transaxle fluid level dipstick

(Vehicle with Automatic Transaxle)

11. Battery

6- 4 DO-IT-YOURSELF MAINTENANCE

G010C01O-AAT ENGINE COMPARTMENT (3.5 V6)

10

11

HSM424

1. Coolant reservoir cap 2. Brake fluid reservoir 3. Air cleaner 4. Fuse and Relay box

5. Windshield washer fluid reservoir 6. Power steering fluid reservoir 7. Engine oil filler cap 8. Radiator cap

9. Engine oil level dipstick 10. Automatic transaxle fluid level dipstick 11. Battery

G020A01A-AAT GENERAL CHECKS Engine Compartment

The following should be checked regularly:

o Engine oil level and condition o Transaxle fluid level and condition o Brake fluid level o Clutch fluid level o Engine coolant level o Windshield washer fluid level o Accessory drive belt condition o Engine Coolant hose condition o Fluid leaks (on or below components) o Power steering fluid level o Battery condition o Air filter condition

G020B01A-AAT Vehicle Exterior

G020C01A-AAT Vehicle Interior

DO-IT-YOURSELF MAINTENANCE 6- 5

The following should be checked monthly:

o Overall appearance and condition o Wheel condition and wheel nut torque o Exhaust system condition o Light condition and operation o Windshield glass condition o Wiper blade condition o Paint condition and body corrosion o Fluid leaks o Door and hood lock condition o Tire pressure and condition (including spare

tire)

The following should be checked each time when the vehicle is driven:

o Lights operation o Windshield wiper operation o Horn operation o Defroster, heating system operation (and air

conditioning, if installed)

o Steering operation and condition o Mirror condition and operation o Turn signal operation o Accelerator pedal operation o Brake operation, including parking brake o Manual transaxle operation, including clutch

operation

o Automatic transaxle operation, including

"Park" mechanism operation

o Seat control condition and operation o Seat belt condition and operation o Sunvisor operation

If you notice anything that does not operate correctly or appears to be functioning incor- rectly, inspect it carefully and seek assistance from your Hyundai dealer if service is needed.

6- 6 DO-IT-YOURSELF MAINTENANCE

G030A01A-AAT CHECKING THE ENGINE OIL

G030C02A-AAT To Check the Oil Level

2.4 DOHC

2.7 V6

Engine oil is essential to the performance and service of the engine. It is suggested that you check the oil level at least once a week in normal use and more often if you are on a trip or driving in severe conditions.

G030B01A-AAT Recommended Oil

Wait five minutes , then remove the dipstick, wipe it off, fully reinsert the dipstick and withdraw it again. Then note the highest level the oil has reached on the dipstick. It should be between the upper ("F") and lower ("L") range.

G030D01A-AAT Adding Oil

2.4 DOHC

2.7 V6

3.5 V6

HSM389

HSM387

HSM395
SH, SG or SG/CD (API) multi-grade and fuel efficient oil is recommended.

HSM427

Before checking the oil, warm up the engine to the normal operating temperature and be sure your car is parked on level ground. Turn the engine off.

3.5 V6

G040A03A-GAT CHANGING THE OIL AND FILTER

2.4 DOHC

2.7 V6

DO-IT-YOURSELF MAINTENANCE 6- 7

The engine oil and filter should be changed at those intervals specified in the maintenance schedule in Section 5. If the car is being driven in severe conditions, more frequent oil and filter changes are required.

The procedure for changing the oil and filter is as follows:

If the oil level is close to or below the "L" mark, add oil until it reaches the "F" mark. To add oil:

HSM426

1. Remove the oil filler cap by turning it counter-

2. Add oil, then check the level again. Do not

clockwise.

overfill.

3. Replace the cap by turning it clockwise.

3.5 V6

HSM394

filler cap.

1. Park the car on level ground and set the parking brake. Start the engine and let it warm up until the needle on the coolant temperature gauge moves above the lowest mark. Turn the engine off and place the gear selector lever in "P" (automatic) or reverse gear (manual transaxle).

2. Open the hood and remove the engine oil

3. Slide underneath the car and loosen the drain plug by turning it counterclockwise with a wrench of the proper size. Be sure that a drain pan is in position to catch the oil as it drains out, then remove the drain plug.

The distance between the "F" and "L" marks is equal to about 1 quart of oil.

WARNING:

Be very careful when draining the engine oil as it may be hot enough to burn you!

G040A02L

6- 8 DO-IT-YOURSELF MAINTENANCE

4. When the oil has stopped draining, replace the drain plug using a new washer and retighten by turning it clockwise.

Oil pan drain plug tightening torque: 3.5 ~ 4.5 kgf.m

6.

5. Remove the oil filter by turning it counter- clockwise with a oil filter wrench of the proper size. A certain amount of oil will come out when you remove the filter. So be sure to have your drain pan in place underneath it. Install a new oil filter in accordance with the instructions on the carton or on the filter itself. Do not over-tighten. (Tightening torque : 1.2 ~ 1.6 kgf.m) Be sure that the mounting surface on the engine is clean and that the old gasket is removed completely. Lubricate the new gasket on the filter with clean engine oil before installation.

7. Refill the crankcase with the recommended engine oil. Refer to the specification in chap- ter 9 for engine oil capacity.

8. Start the engine and check to be sure no oil

is leaking from the drain plug or oil filter.

9. Shut off the engine and recheck the oil level.

NOTE: Always dispose of used engine oil in an environmentally acceptable manner. It is suggested that it be placed in a sealed container and taken to a service station for reclamation. Do not pour the oil on the ground or put it in with the household trash.

WARNING:

Used motor oil may cause irritation or can- cer of the skin if left in contact with the skin for prolonged periods of time. Wash your hands thoroughly with soap and warm water as soon as possible after handling used oil.

G050A01A-AAT CHECKING AND CHANGING THE EN- GINE COOLANT

WARNING:

Do not remove the radiator cap when the engine is hot. When the engine is hot, the engine coolant is under pressure and may erupt through the opening if the cap is removed. You could be seriously burned if you do not observe this precaution. Do not remove the radiator cap until the radiator is cool to the touch.

G050B01A-AAT Recommended Engine Coolant

G050B01O Use a high quality ethylene-glycol coolant in a 50/50 mix with water. The engine coolant should be compatible with aluminum engine parts. Additional corrosion inhibitors or additives should not be used. The cooling system must be maintained with the correct concentration and type of engine coolant to prevent freezing and corrosion. Never allow the concentration of antifreeze to exceed the 60% level or go below the 35% level, or damage to the cooling system may result. For proper concentration when adding or replacing the engine coolant, refer to the following table.

Ambient

Engine Coolant concentration

temperature

°C ( °F) -15 (5) -25 (-13) -35 (-31) -45 (-49)

Antifreeze solution

35% 40% 50% 60%

Water

65% 60% 50% 40%

G050C01A-AAT To Check the Coolant Level

G050C01O The coolant level can be seen on the side of the plastic coolant reservoir. The level of the cool- ant should be between the "L" and "F" lines on the reservoir when the engine is cool. If the level is below the "L" mark, add engine coolant to bring it up between "L" and "F". If the level is low,

inspect for coolant leaks and recheck the fluid level frequently. If the level drops again, visit your Hyundai dealer for an inspection and diagnosis of the reason.

G050D02A-AAT To Change the Engine Coolant

The engine coolant should be changed at those intervals specified in the vehicle maintenance schedule in Section 5.

CAUTION: Engine coolant can damage the finish of your car. If you spill engine coolant on the car, wash it off thoroughly with clean water.

1. Park the car on level ground, set the park- ing brake and remove the radiator cap when cool.

2. Be sure your drain receptacle is in place. Open the drain cock on the radiator. Allow all the engine coolant to drain from the cooling system, then securely close the drain cock. 3. Check Section 9 for the capacity of the cooling system in your car. Then, following the manufacturer's directions on the engine coolant container, add the appropriate quan- tity of coolant to the radiator.

DO-IT-YOURSELF MAINTENANCE 6- 9

G050D01O 4. Turn the radiator cap counterclockwise with- out pressing down on it, until it stops. This relieves any pressure remaining in the cool- ing system. And remove the radiator cap by pushing down and turning counterclock- wise. Now fill the radiator with clean demineralized or distilled water. Continue to add clean demineralized or distilled water in small quan- tities until the fluid level stays up in the radiator neck.

6- 10 DO-IT-YOURSELF MAINTENANCE

G060A01O-AAT SPARK PLUGS

2.4 DOHC

2.7 V6 / 3.5 V6

HSM392

Your engine was originally equipped with plati- num-tipped spark plugs. Platinum-tipped spark plugs will last longer than conventional type spark plugs and can be identified by blue lines on the ceramic shell.

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

G050D02O 5. Start the engine, top off the radiator with water and then add coolant to the reservoir until the level is between "L" and "F".

6. Replace the radiator and reservoir caps and check to be sure the drain cocks are fully closed and not leaking.

WARNING:

The cooling fan is controlled by engine coolant temperature and may sometimes operate even when the engine is not run- ning. Use extreme caution when working near the blades of the coolant fan so that you are not injured by a rotating fan blade. As the engine coolant temperature de- creases, the fan will automatically shut off. This is a normal condition.

G060B02O-AAT Replacing the Spark Plugs

The spark plugs should be changed at the intervals specified in the vehicle maintenance schedule in Section 5 or whenever engine performance indicates they should be changed. Symptoms that suggest poor spark plug perfor- mance include engine misfiring under load, loss of fuel economy, poor acceleration, etc. When spark plugs are replaced, always use spark plugs recommended by Hyundai. The use of other spark plugs can result in loss of perfor- mance, radio interference or engine damage.

NOTE: o When replacing the spark plugs, genu- ine Hyundai replacement parts are rec- ommended.

o It is recommended that the spark plug should be changed by an authorized Hyundai dealer. (2.7 L, 3.5 L)

Recommended Spark Plugs:

Type

RN10PYP4 (CHAMPION) PGR5C-11 (NGK) RC10PYPB4 (CHAMPION) PFR5N-11 (NGK)

Remark

2.4 L

2.7 L / 3.5 L

G060C0IO-AAT Changing the Spark Plugs

DO-IT-YOURSELF MAINTENANCE 6- 11

G060C02O

G060C03O

G060C01O You will find it easier to change spark plugs if the engine is cold. Always change one spark plug at a time. This helps avoid getting the wires mixed up.

1. Remove the center cover (2.4 L) on the

engine rocker cover.

2. Using a clean cloth, remove any dirt that has accumulated around the base of the spark plug so it cannot fall into the cylinder when the spark plug is removed.

3. To remove the spark plug cable, pull straight up on the insulated connector, not the cable. Pulling on the cable may damage the carbon core conductor.

WARNING:

It is recommended that the engine be cool or cold when changing the spark plugs. If the engine is hot, you could burn yourself on the insulated connector, the spark plug or the engine itself.

4. When preparing to remove the old spark plug, guide the socket down over the spark plug, being careful not to damage the ce- ramic insu lator.

5. To remove the old spark plug, turn the wrench handle in a counterclockwise direc- tion.

6. To install the new spark plug, guide the socket down over the spark plug, being careful not to damage the ceramic insulator.

NOTE: Spark plugs should be tightened to speci- fication. Over-tightening can damage the threads in the aluminum cylinder head. Also, leaving them too loose can cause the spark plug to get very hot and possibly result in damage to the engine.

7. Replace the cable by pushing the insulated connector directly down onto the electrode. Check to be sure it has snapped into place and can't fall off.

6- 12 DO-IT-YOURSELF MAINTENANCE

G070A02Y-AAT CHANGING THE AIR CLEANER FILTER

G080A02A-AAT WINDSHIELD WIPER BLADES

G090A01O-AAT FILLING THE WASHER RESERVOIR

G070A01O The replacement of air cleaner filter is per- formed 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 removed and the new filter put in its place.

Genuine Hyundai replacement parts are rec- ommended.

CAUTION:

Operating your vehicle without a proper air cleaner filter in place can result in excessive engine wear.

HEF119
The wiper blades should be carefully inspected from time to time and cleaned to remove accu- mulations of road film or other debris. To clean the wiper blades and arms, use a clean sponge or cloth with a mild soap or detergent and water. If the wipers continue to streak or smear the glass, replace them with genuine Hyundai re- placement parts or their equivalent.

NOTE: o Do not operate the wipers on dry glass. This can result in more rapid wear of the wiper blades and may scratch the glass. o Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc.

G090A01O The washer fluid reservoir supplies fluid to the windshield washer system. A good quality washer fluid should be used to fill the washer reservoir. The fluid level should be checked more frequently during bad weather or whenever the washer system is in more fre- quent use. The capacity of the washer reservoir is 3.59
U.S. quarts (3.4 Liters).

CAUTION:

o Radiator anti-freeze (engine coolant) should not be used in the washer system because it will damage the car's finish. o The washer lever should not be pulled and the washer should not be operated if the washer reservoir is empty. This can damage the washer fluid pump.

G100A02O-AAT CHECKING THE TRANSAXLE OIL (MANUAL)

Filler plug

Drain plug

HSM435
Transaxle lubricant in the manual transaxle should be checked at those intervals specified in the vehicle maintenance schedule in Section 5.

Recommended Oil

Use only HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4) or EQUIVALENT in the manual transaxle.

WARNING:

It is always better to check the transaxle oil level when the engine is cool or cold. If the engine is hot, you should exercise great caution to avoid burning yourself on hot engine or exhaust parts.

DO-IT-YOURSELF MAINTENANCE 6- 13

2. Use your finger or suitable tool to feel inside the hole. The oil level should be at its bottom edge. If it is not, check for leaks before adding oil. To refill the transaxle or bring the oil level up,add oil slowly until it reaches the proper level. Do not overfill.

3. Replace the plug and washer, screw it in with your fingers and then tighten securely with the wrench.

G100B02A-AAT To Check the Manual Transaxle Fluid Level

G110A01A-AAT CHECKING THE TRANSAXLE FLUID (AUTOMATIC)

Transaxle fluid in the automatic transaxle should be checked at those intervals specified in the vehicle maintenance schedule in Section 5.

G110B03A-AAT Recommended Fluid

Your Hyundai automatic transaxle is specially designed to operate with HYUNDAI GENUINE ATF or DIAMOND ATF SP-III or SK ATF SP-III. Damage caused by a nonspecified fluid is not covered by your new vehicle limited warranty.

SSA6100B

Manual Transaxle Oil Capacity

Park the car on level ground with the engine off.

The oil capacity of the manual transaxle is 2.43
U.S. quarts (2.3 liters).

1. Using a wrench of the correct size, loosen the oil filler plug by turning it counterclock- wise and remove it with your fingers.

6- 14 DO-IT-YOURSELF MAINTENANCE

G110C01O-AAT Transaxle Fluid Capacity

G110D02Y-AAT To Check the Transaxle Fluid Level

2.4 DOHC

2.7 V6

The fluid capacity of the automatic transaxle is 8.98 U.S. quarts (8.5 liters).

WARNING:

The transaxle fluid level should be checked when the engine is at normal operating temperature. This means that the engine, radiator, exhaust system etc., are very hot so you should exercise great care not to burn yourself during this procedure.

C090A01O Park the car on level ground with the parking brake engaged. When the transaxle fluid level is checked, the transaxle fluid should be at normal operating temperature and the engine idling.

3.5 V6

HSM388

HSM425
While the engine is idling, apply the brakes and move the gear selector lever from "P" to each of its other positions — "R", "N", "D", "2", "3", "L" — and then return to "N" or "P". With the engine still idling:

1. Open the hood, being careful to keep hands, long hair and clothing clear of any moving parts.

2. Remove the transaxle dipstick, wipe it clean, reinsert the dipstick as far as it will go, then remove it again. Now check the fluid level on the dipstick. It should be in the "HOT" range on the dipstick. If the transaxle fluid level is low, use a funnel to add transaxle fluid through the dipstick tube until the level reaches the "HOT" range. Do not overfill.

3.

WARNING:

The cooling fan is controlled by engine coolant temperature and may sometimes operate even when the engine is not run- ning. Use extreme caution when working near the blades of the cooling fan, so that you are not injured by a rotating fan blade. As the engine coolant temperature de- creases, the fan will automatically shut off. This is a normal condition.

Fluid level should be within "HOT" range

G120A01A-AAT CHECKING THE BRAKES

CAUTION:

Because brakes are essential to the safe operation of the car, it is suggested that they be checked and inspected by your Hyundai dealer. The brakes should be checked and inspected for wear at those intervals specified in the vehicle mainte- nance schedule in Section 5.

G110D03Y

DO-IT-YOURSELF MAINTENANCE 6- 15

G120B01A-AAT Checking the Brake Fluid Level

WARNING:

Use caution when handling brake fluid. It can damage your vision if it gets into your eyes. It will also damage your vehicle's paint if spilled on it and not removed imme- diately.

G120C02A-AAT Recommended Brake Fluid

Use only hydraulic brake fluid conforming to DOT 3 or DOT 4 specifications in your braking system. Follow the instructions printed on the container.

6- 16 DO-IT-YOURSELF MAINTENANCE

G120D01A-AAT To Check the Fluid Level

The fluid level in the brake fluid reservoir should be checked periodically. The level should be between the "MIN" and "MAX" marks on the side of the reservoir. If the level is at or below the "MIN" mark, carefully add fluid to bring it up to "MAX". Do not overfill.

G120E02A-AAT Adding Brake Fluid

WARNING:

Handle brake fluid carefully. It can damage your vision if it gets into your eyes. Use only DOT 3 or DOT 4 specification fluid from a sealed container. Do not allow the fluid can or reservoir to remain open any longer than required. This will prevent entry of dirt and moisture which can damage the brake sys- tem and cause improper operation.

G130A01A-AAT CHECKING THE CLUTCH FLUID To Check the Clutch Fluid

To add brake fluid, first wipe away any dirt then unscrew the fluid reservoir cap. Slowly pour the recommended fluid into the reservoir. Do not overfill. Carefully replace the cap on the reser- voir and tighten.

HSM158

HSM158
The clutch fluid level in the master cylinder