2003 Hyundai Tiburon Owners Manual

SEE NOTE *2

Note : *1 - FOR CALIFORNIA, THIS MAINTENANCE IS RECOMMENDED, BUT NOT REQUIRED *2 - FOR EVERY 12 MONTHS OR 12,000 MILES (20,000 KM), WHICHEVER OCCURS FIRST : "R"

5- 4

VEHICLE MAINTENANCE REQUIREMENTS

F040A01GK-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

ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS BRAKE PADS, CALIPERS AND ROTORS REAR BRAKE DRUMS/LININGS/PADS, PARKING BRAKE STEERING GEAR RACK, LINKAGE & BOOTS/ LOWER ARM BALL JOINT DRIVESHAFTS AND BOOTS MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID AIR FILTER (FOR BLOWER UNIT)

MAINTENANCE INTERVALS

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

MORE FREQUENTLY

MORE FREQUENTLY

DRIVING

CONDITION

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) MORE FREQUENTLY

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

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

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 for patrol car, taxi, commercial car or vehicle towing

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VEHICLE MAINTENANCE REQUIREMENTS

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.

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

tions

F060F01A-AAT o Vacuum, Crankcase

Ventilation Hoses

Inspect the surface of hoses for evidence of heat and/or mechanical damage. Hard and brit- tle rubber, cracking, tears, cuts, abrasions, and excessive swelling indicate deterioration. Par- ticular attention should be paid to examine those hose surfaces nearest to high heat sourc- es, 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.

F060G01A-AAT o Vapor Hose and Fuel Filler Cap 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.

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

F060H01A-AAT o Air cleaner filter A Genuine Hyundai air cleaner filter is recom- mended when filter is replaced.

5- 6

F060J01A-AAT o Spark plugs Make sure to install new spark plugs of the correct heat range.

F060B02A-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.

F070C01A-AAT o Coolant The coolant should be changed at the intervals specified in the maintenance sched- ule.

F060E01A-AAT o Timing belt Inspect all parts related to the timing belt for damage and deformation. Replace any dam- aged parts immediately.

F070D01A-AAT o Manual transaxle oil 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.

VEHICLE MAINTENANCE REQUIREMENTS

F070E04A-AAT o Automatic Transaxle Fluid 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 HYUNDAI GENUINE ATF, DIAMOND ATF SP-III, 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 immediately.

F070G02A-AAT o Brake Fluid 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.

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.

F070K01A-AAT o Exhaust Pipe and Muffler 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.

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.

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. Re- place 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 condi- tioning performance according to the relevant shop manual if necessary.

F060N01E-AAT o Valve Clearance Inspect excessive valve noise and/or engine vibration and adjust if necessary. A qualified technician should perform the operation.

Valve Clearance Intake valves : 0.0067 ~ 0.0091 in. (0.17 ~ 0.23mm) Exhaust valves : 0.0098 ~ 0.0122 in. (0.25 ~ 0.31mm)

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DO-IT-YOURSELF MAINTENANCE

6. DO-IT-YOURSELF MAINTENANCE

G010A01GK-AAT ENGINE COMPARTMENT (2.0 DOHC)

CAUTION: When inspecting or servicing the engine, you should handle tools and other heavy objects carefully so that the plastic rocker cover of the engine is not damaged.

10

11

12

13

HGK059

1. Engine oil filler cap 2. Brake Booster 3. Brake fluid reservoir 4. Clutch fluid reservoir (If installed) 5. Relay box

6. Windshield washer fluid reservoir cap 7. Power steering fluid reservoir 8. Engine coolant reservoir 9. Engine oil level dipstick 10.Radiator cap

11.Automatic transaxle fluid level dipstick

(If installed) 12.Air cleaner 13.Battery

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DO-IT-YOURSELF MAINTENANCE

G010B01GK-GAT ENGINE COMPARTMENT (2.7 V6)

7 8

10

11

12

HGK209

1. Power steering fluid reservoir 2. Brake Booster 3. Brake fluid reservoir 4. Air Cleaner

6-2

5. Relay box 6. Windshield washer fluid reservoir cap 7. Engine coolant reservoir 8. Engine oil level dipstick

9. Radiator cap 10.Engine oil filler cap 11.Automatic transaxle fluid level dipstick

(If installed)

12.Battery

DO-IT-YOURSELF MAINTENANCE

G020C01A-AAT Vehicle Interior 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 incorrect- ly, inspect it carefully and seek assistance from your Hyundai dealer if service is needed.

G030A01A-AAT CHECKING THE ENGINE OIL 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

20W-40 20W-50

10W-30 10W-40 10W-50

5W-30 5W-40

°F

°C

-20

-9

20

32

-29

-23

-18

-7

60

16

85

95

100

27

35

38

G030B01A

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

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

G020B01A-AAT Vehicle Exterior The following should be checked monthly: o Overall appearance and condition o Wheel condition and wheel nut torque o Air filter condition 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)

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DO-IT-YOURSELF MAINTENANCE

G030C01A-AAT To Check the Oil Level

G030D01A-AAT Adding Oil

DOHC

V6

DOHC

V6

G040A02GK-AAT CHANGING THE OIL AND FILTER

DOHC

V6

HGK210

HGK211

G040A01GK

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. Wait a minute, 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 ("FULL") and lower ("LOW") range.

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

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

clockwise.

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

overfill.

3. Replace the cap by turning it clockwise.

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

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:

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). Set the parking brake.

2. Open the hood and remove the engine oil

filler cap.

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DO-IT-YOURSELF MAINTENANCE

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.

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

4. When the oil has stopped draining, replace the drain plug using a new washer and retighten by turning it clockwise. Tightening torque is: 4.5 ~ 4.0 kgf.m (2.0L) 4.5 ~ 3.5 kgf.m (2.7L)

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 under- neath 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 gas- ket 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 sug- gested that it be placed in a sealed container and taken to a service station for reclama- tion. Do not pour the oil on the ground or put it into 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 wa- ter 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

HGK187

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 main- tained with the correct concentration and type of engine coolant to prevent freezing and corro- sion. Never allow the concentration of anti- freeze to exceed the 60% level or go below the 35% level, or damage to the cooling system may result. For proper concentration when add- ing or replacing the engine coolant, refer to the following table.

6-5

Ambient

temperature

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

Engine Coolant concentration

Antifreeze solution

35% 40% 50% 60%

Water

65% 60% 50% 40%

G050C01A-AAT To Check the Coolant Level The coolant level can be seen on the side of the plastic coolant reservoir. The level of the cool- ant should be between the "LOW" and "FULL" lines on the reservoir when the engine is cold. If the level is below the "LOW" mark, add engine coolant to bring it up between "LOW" and "FULL". If the level is low, inspect for coolant leaks and recheck the fluid level fre- quently. If the level drops again, visit your Hyundai dealer for an inspection and diagnosis of the reason.

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DO-IT-YOURSELF MAINTENANCE

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.

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 counterclockwise. Now fill the radiator with clean demineral- ized 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.

5. 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 cool- ant temperature and may sometimes oper- ate even when the engine is not running. 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 en- gine coolant temperature decreases, the fan will automatically shut off. This is a normal condition.

G060A01GK-AAT SPARK PLUGS

DOHC

V6

YN60100A

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.

G060C01GK-GET Changing the Spark Plugs

DO-IT-YOURSELF MAINTENANCE

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

G060B01GK-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 per- formance 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: When replacing the spark plug, always use the genuine parts recommended.

Recommended Spark Plugs:

Type

RC10YC4(CHAMPION) BKR5ES-11(NGK)

RC10PYPB4(CHAMPION) PFR5N-11(NGK)

Remark

2.0L

2.7L

G060C01GK

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 (2.0 L) cover on the

engine rocker cover.

NOTE: It is recommended that the spark plugs (For 2.7L Engines) should be changed by an authorized Hyundai dealer.

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.

G060C02GK

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 insulator.

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.

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DO-IT-YOURSELF MAINTENANCE

G070A01GK-AAT CHANGING THE AIR CLEANER FIL- TER

G080A02A-AAT WINDSHIELD WIPER BLADES

G060C03GK

NOTE: Spark plugs should be tightened firmly. 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.

6-8

HGK213

To change the filter, unsnap the clips around the cover. 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 recommended.

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

o Be careful that dust or dirt does not enter

the air intake, or damage may result.

HEF-119

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 Replacement Parts or their equivalent.

CAUTION: 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.

DO-IT-YOURSELF MAINTENANCE

G090A01A-AAT FILLING THE WASHER RESERVOIR

G100A02GK-AAT CHECKING THE TRANSAXLE OIL (MANUAL)

G100B01A-AAT To Check the Manual Transaxle Fluid Level

HGK217

Filler plug

Drain plug

G110A01E

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 3.2 U.S. quarts (3.0 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.

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 equivalents in the manual transaxle.

Manual Transaxle Oil Capacity The oil capacity of the manual transaxle: 2.3 us quarts (2.15L)

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.

SSA6100B

Park the car on level ground with the engine off. 1. Using a wrench of the correct size, loosen the oil filler plug by turning it counterclock- wise and remove it with your fingers.

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, screw it in with your fin- gers and then tighten securely with the wrench.

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DO-IT-YOURSELF MAINTENANCE

G110D02Y-AAT To Check the Transaxle Fluid Level

HGK174
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.

DOHC

V6

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" — 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.

Fluid level should be within this range

(cid:0)(cid:0)

HGK212

HGK249

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, DIAMOND ATF SP-III or SK ATF SP-III. Damage caused by a nonspecified fluid is not covered by your new vehicle limited warranty.

G110C02Y-AAT Transaxle Fluid Capacity The fluid capacity of the automatic transaxle is 8.2 U.S. quarts (7.8 liters).

WARNING: The transaxle fluid level should be checked when the engine is at normal operating tem- perature. This means that the engine, radia- tor, exhaust system etc., are very hot. Exer- cise great care not to burn yourself during this procedure.

6-10

WARNING: The cooling fan is controlled by engine cool- ant temperature and may sometimes oper- ate even when the engine is not running. 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 en- gine coolant temperature decreases, the fan will automatically shut off. This is a normal condition.

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.

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 immediately.

DO-IT-YOURSELF MAINTENANCE

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.

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.

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.

G130A01S-AAT CHECKING THE CLUTCH FLUID To Check the Clutch Fluid

HGK215

HGK216

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DO-IT-YOURSELF MAINTENANCE

accumulation of dirt, dead insects, leaves, etc. These can interfere with maximum cooling effi- ciency. When removing such accumulations, brush or hose them away carefully to avoid bending the cooling fins.

G140B01A-AAT Checking the Air Conditioning Opera- tion 1. Start the engine and let it run at a fast idle for several minutes with the air conditioning set at the maximum cold setting. If the air coming out of the in-dash vents is not cold, have the air conditioning system inspected by your Hyundai dealer.

2.

CAUTION: Running the air conditioning system for extended periods of time with a low refriger- ant level may damage the compressor.

G140C01A-AAT Lubrication To lubricate the compressor and the seals in the system, the air conditioning should be run for at least 10 minutes each week. This is particularly important during cool weather when the air conditioning system is not otherwise in use.

G140D01A-AAT Checking the Compressor Drive Belt

DOHC

A/C

0.315 in. (8 mm)

V6

Auto tensioner

CRANK PULLEY

TENSION PULLEY

Eng.pulley

COMP G140D01GK

When the air conditioning is being used regular- ly, the compressor drive belt tension should be checked at least once a month with the engine turned off. To check the drive belt tension, press down on the belt halfway between the engine crankshaft and compressor pulleys. Pressing with your finger, you should not be able to deflect this belt anymore than 1/3 of an inch. If you have the instruments to check it, with a force of 22 lb. (98N), the deflection should be 0.315 inches (approx 8.0 mm). If the belt is too loose, have it adjusted by your Hyundai dealer.

The clutch fluid level in the master cylinder should be checked when performing other un- der hood services. The system should be checked for leakage at the same time. Check to make certain that the clutch fluid level is always between the "MAX" and "MIN" level markings on the fluid reservoir. Fill as required. Fluid loss indicates a leak in the clutch system which should be inspected and repaired imme- diately. Consult your Hyundai dealer.

G130B02A-AAT To Replace the Fluid Recommended brake fluid conforming to DOT 3 or DOT 4 specification should be used. The reservoir cap must be fully tightened to avoid contamination from foreign matter or moisture.

NOTE: Do not allow any other liquids to contami- nate the brake fluid. Seal damage will result.

WARNING: Use caution when handling brake fluid. It can damage your vision if you get it in your eyes. It will also damage your vehicle’s paint if spilled on it and not removed immediately.

G140A01A-AAT AIR CONDITIONING CARE Keeping the Condenser Clean The air conditioning condenser (and engine radiator) should be checked periodically for 6-12

DO-IT-YOURSELF MAINTENANCE

G150A01A-AAT CHECKING STEERING WHEEL FREE-PLAY

G160A01A-AAT CHECKING CLUTCH PEDAL FREE-PLAY

G170A01A-AAT CHECKING BRAKE PEDAL FREE-PLAY

1.18in (30 mm)

0.24~0.51 in. (6~13 mm)

0.12~0.31 in. (3~8 mm)

HGK218

SSA6160A

SSA6170A

To check the steering wheel free-play, stop the car with the wheels pointed straight ahead and gently move the steering wheel back and forth. Use very light finger pressure and be sensitive to changes in resistance that mark the limits of the free-play. If the free-play is greater than specified, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.

With the engine off, press lightly on the clutch pedal until you feel a change in resistance. This is the clutch pedal free-play. The free-play should be within the limits specified in the illustration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.

With the engine off, press down on the brake pedal several times to reduce the vacuum in the brake booster. Then, using your hand, press down slowly on the brake pedal until you feel a change in resistance. This is the brake pedal free-play. The free-play should be within the limits speci- fied in the illustration. If it is not, have it inspect- ed by your Hyundai dealer and adjusted or repaired if necessary.

6-13

G180A01A-AAT CHECKING BRAKE PEDAL CLEARANCE

DO-IT-YOURSELF MAINTENANCE

G190A01A-AAT CHECKING DRIVE BELTS

DOHC

V6

Water Pump Pulley

0.2 ~ 0.24 in. (5.1 ~ 6 mm)

Power steering

Auto tensioner

G200A01A-AAT CHECKING AND REPLACING FUSES Replacing a Fusible Link

1.78 in. (45.1 mm)

Bad

Good

SSA6180A

You need a helper to check the brake pedal clearance. With the engine running, have your helper press down on the brake pedal several times and then hold it down with a force of about 110 lbs (50 kg, 490 N). The brake pedal clear- ance is the distance from the top surface of the brake pedal to the asphalt sheeting under the floor mat. If the brake pedal clearance is not within the limits specified in the illustration, have it in- spected by your Hyundai dealer and adjusted or repaired if necessary.

Generator Pulley

Crankshaft Pulley

Generator

Eng.pulley

COMP G190A01GK

Drive belts should be checked periodically for proper tension and adjusted if necessary. At the same time, belts should be examined for cracks, wear, fraying or other evidence of deterioration and replaced if necessary. Belt routing should also be checked to be sure there is no interference between the belts and other parts of the engine. After a belt is re- placed, the new belt should be adjusted again after two or three weeks to eliminate slack resulting from initial stretching after use.

6-14

AS60310A

A fusible link will melt if the electrical circuits from the battery are ever overloaded, thus pre- venting damage to the entire wiring harness. (This could be caused by a short in the system drawing too much current.) If this ever happens, have a Hyundai dealer determine the cause, repair the system and replace the fusible link. The fusible links are located in a relay box for easy inspection.

CAUTION: When replacing a fusible link, never use anything but a new fusible link with the same or lower amperage rating. Never use a piece of wire or a higher-rated fusible link. This could result in serious damage and create a fire hazard.

G200B02A-AAT Replacing Accessory Fuse

DO-IT-YOURSELF MAINTENANCE

HGK185

The fuse box for the lights and other electrical accessories will be found low on the dashboard on the driver’s side. Inside the box you will find a list showing the circuits protected by each fuse. If any of your car’s lights or other electrical accessories stop working, a blown fuse could be the reason. If the fuse has burned out, you will see that the metal strip inside the fuse has burned through. If you suspect a blown fuse, follow this procedure:

1. Turn off the ignition and all other switches. 2. Open the fuse box and examine each fuse. Remove each fuse by pulling it toward you (a small "fuse puller" tool is contained in the fuse box to simplify this operation).

3. Be sure to check all other fuses even if you find one that appears to have burned out.

AXA6201B

Good

Burned out

G200B03Y

4. Replace the blown fuse by pressing a new fuse of the same rating into place. The fuse should be a snug fit. If it is not, have the fuse clip repaired or replaced by a Hyundai dealer. If you do not have a spare fuse, you may be able to borrow a fuse of the same or lower rating from an accessory you can tempo- rarily get along without (the radio or cigarette lighter, for example). Always remember to replace the borrowed fuse.

CAUTION: A burned-out fuse indicates that there is a problem in the electrical circuit. If you re- place a fuse and it blows as soon as the accessory is turned on, the problem is seri- ous and should be referred to a Hyundai dealer for diagnosis and repair. Never re- place a fuse with anything except a fuse with the same or a lower amperage rating. A higher capacity fuse could cause damage and create a fire hazard.

NOTE: See page 6-20 for the fuse panel descrip- tions.

6-15

DO-IT-YOURSELF MAINTENANCE

G210A01A-AAT CHECKING THE BATTERY

WARNING: Batteries can be dangerous! When working with batteries, carefully observe the follow- ing precautions to avoid serious injuries.

The fluid in the battery contains a strong solu- tion of sulfuric acid, which is poisonous and highly corrosive. Be careful not to spill it on yourself or the car. If you do spill battery fluid on yourself, immediately do the following:

o If battery fluid is on your skin, flush the affected areas with water for at least 15
minutes and then seek medical assistance. o If battery fluid is in your eyes, rinse out your eyes with water and get medical assistance as soon as possible. While you are being driven to get medical assistance, continue to rinse your eyes by using a sponge or soft cloth saturated with water.

o If you swallow battery fluid, drink a large quantity of water or milk followed by milk of magnesia, eat a raw egg or drink vegetable oil. Get medical assistance as soon as possible.

While batteries are being charged (either by a battery charger or by the vehicle’s generator), they produce explosive gases. Always observe these warnings to prevent injuries from occur- ring:

6-16

o Charge batteries only in a well ventilated

area.

o Do not permit flames, sparks or smoking in

the area.

o Keep children away from the area.

G210B02A-AAT Checking the Battery Keep the battery clean. Any evidence of corro- sion around the battery posts or terminals should be removed using a solution of household bak- ing soda and warm water. After the battery terminals are dry, cover them with a light coat- ing of grease.

PROPOSITION 65 WARNING: Battery posts, terminals, and related acces- sories contain lead and lead compounds, chemicals known to the state of California to cause cancer and reproductive harm. Wash hands after handling.

G220A01A-AAT CHECKING ELECTRIC COOLING FANS

WARNING: The cooling fan is controlled by engine cool- ant temperature and may sometimes oper- ate even when the engine is not running. 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 en- gine coolant temperature decreases the fan will automatically shut off. This is a normal condition.

G220B01A-AAT Checking Engine Cooling Fan The engine cooling fan should come on auto- matically if the engine coolant temperature is high.

G220C01A-AAT Checking Condenser Cooling Fan The condenser coolant fan should come on automatically whenever the air conditioning is in operation.

G230A03A-AAT POWER STEERING FLUID LEVEL

HGK214

The power steering fluid level should be checked regularly. To check the power steering fluid level, be sure the engine is "OFF", then check to make certain that the power steering fluid level is between the "MAX" and "MIN" level markings on the fluid reservoir.

NOTE: Grinding noise from the power steering pump may be heard immediately after the engine is started in extremely cold condi- tions (below - 4°F). If the noise stops during warm up, there is no abnormal function in the system. It is due to a power steering fluid characteristic in extremely cold condi- tions.

Recommended Fluid Use PSF-3 type fluid

NOTE: Do not start the engine when the power steering oil reservoir is empty.

G240A01A-AAT POWER STEERING HOSES It is suggested that you check the power steer- ing hose connections for fluid leakage at regular intervals. The power steering hoses should be replaced if there is severe surface cracking, scuffing or worn spots. Deterioration of the hose could cause premature failure.

G250A01A-AAT FOR MORE INFORMATION ABOUT YOUR HYUNDAI If you desire additional information about main- taining and servicing your Hyundai, you may purchase a factory Shop Manual at your Hyundai dealer's parts department. This is the same

DO-IT-YOURSELF MAINTENANCE

manual used by dealership technicians and while it is highly technical it can be useful in obtaining a better understanding of your car and how it works.

G260A02A-AAT REPLACING HEADLIGHT BULBS Before attempting to replace a headlight bulb, be sure the switch is turned to the "OFF" position. The next paragraph shows how to reach head- light bulbs so they may be changed. Be sure to replace the burned-out bulb with one of the same number and wattage rating.

CAUTION: Keep the lamps out of contact with petro- leum products such as oil, gasoline etc.

G270A02A-GAT HEADLIGHT BULB Replacement instructions:

Turn signal Light

1. Allow the bulb to cool. Wear eye protection. 2. Always grasp the bulb by its plastic base,

avoid touching the glass.

3. Disconnect the power cord from the bulb

base in the back of the headlight.

4. Remove the dust cover. 5. Push the bulb spring for removing the head-

light bulb.

6. Remove the protective cap from the re- placement bulb and install the new bulb by matching the plastic base with the headlight hole. Install the dust cover after retightening the bulb spring and reconnect the power cord.

7. Use the protective cap and carton to dis-

pose of the old bulb.

8. Check for proper headlight aim.

WARNING: The halogen bulb contains gas under pres- sure and if impacted could shatter, resulting in flying fragments. Always wear eye pro- tection when servicing the bulb. Protect the bulb against abrasions or scratches and against liquids when lighted. Turn the bulb on only when installed in a headlight. Re- place the headlight if damaged or cracked. Keep the bulb out of the reach of children and dispose of the used bulb with care.

Low Beam

High Beam

HGK225

6-17

DO-IT-YOURSELF MAINTENANCE

G290A02GK-AAT HEADLIGHT AIMING ADJUSTMENT Low Beam

Vertical aiming

Horizontal aiming

G290A03GK

Before performing aiming adjustment, make sure of the following.

1. Keep all tires inflated to the correct pres-

sure.

2. Place the vehicle on level ground and press the front bumper & rear bumper down sev- eral times. Place vehicle at a distance of 118
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 tire, jack, and tools).

4. Clean the head light lenses and turn on the

headlights (low beam).

5. Open the hood. 6. Draw the vertical line (through the center of each headlight beam pattern) and the hori- zontal line (through the center of each head- light beam pattern) on the aiming screen.

6-18

And then, draw the parallel line at 0.827 in. (21 mm) under the horizontal line.

7. Adjust each cut-off line of the low beam to the parallel line with a phillips screwdriver - VERTICAL AIMING.

8. Adjust each cut-off line of the low beam to the each vertical line with a phillips screw- driver - HORIZONTAL AIMING.

WARNING: Horizontal aiming should be adjusted by an authorized Hyundai Dealer.

G290B01GK-AAT Adjustment After Headlight Assembly Replacement

0.827in.(21mm)

Horizontal line

Vertical line

"P"

Cut-off line

Ground line

G290B01GK

If the vehicle has had front body repair and the headlight assembly has been replaced, the headlight aiming should be checked using the aiming screen as shown in the illustration. Turn on the headlight switch.

1. Adjust headlights so that main axis of light is parallel to center line of the body and is aligned with point "P" shown in the illustra- tion.

2. Dotted lines in the illustration show the cen-

ter of headlights.

SPECIFICATION: "H" Horizontal center line of headlights from ground: Low Beam: 26.7 in. (679mm) High Beam: 26.5 in. (672mm)

"W" Distance between each headlight center : Low Beam: 47.3 in. (1,202mm) High Beam: 38.0 in. (966mm)

"L" Distance between the headlights and the wall that the lights are tested against : 118 in. (3,000
mm)

G280A02GK-AAT

DO-IT-YOURSELF MAINTENANCE

(High)

(Low)

10
9 11

12

13

No.

Part Name

Head Light (High/Low)

Map Light

Front Position Light

Front Fog Light (If installed)

Front Turn Signal Light/ Side Marker

Front Door Edge Warning Light

Luggage Compartment Light

Wattage

55/55

10

51

28/8

No.

10

11

12

13

Part Name

High Mounted Without spoiler

Stop Light

Rear

With spoiler

Side-Marker

Combination

Turn Signal Light

Stop/Tail Light

Back-up Light

License Plate Light

HGK035A

Wattage

2.4W (LED)

3.5W (LED)

27

27/8

27

6-19

DO-IT-YOURSELF MAINTENANCE

G200C01GK-GAT FUSE PANEL DESCRIPTION Engine Compartment

DESCRIPTION

FUSE RATING

PROTECTED COMPONENTS

BATT BATT COND RAD ECU IGN

ABS 1
ABS 2

BLOWER

INJ

SNSR DRL F/FOG ECU

HORN,A/CON

H/LP (H1) H/LP (LO)

100A 50A 30A 30A 30A 30A 30A 30A 30A 15A 10A 15A 15A 10A 15A 15A 15A

Generator Generator Condenser Fan Radiator Fan Engine Control, ECM. ATM Control Ignition, Start Relay ABS ABS Blower Injector O2 Sensor, ECM DRL Front Fog Light TCM, ECM Horn. A/Conditioner Head Light (High) Head Light (LOW)

If installed

HGK205-E

NOTE: Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time of printing. When you inspect the fuse box on your vehicle, refer to the fuse box label. 6-20

G200D01GK-GAT Inner Panel

DO-IT-YOURSELF MAINTENANCE

DESCRIPTION

FUSERATING

PROTECTED COMPONENTS

IG COIL

AMP

B/UP LAMP A/BAG IND

A/BAG

HTD MIR HAZARD R/WIPER TAIL-RH F/WIPER A/C SW

RR DEFOG

STOP TAIL-LH A/CON ECU

CLUSTER ROOM LP P/WINDOW

T/GATE

IGN

RR FOG C/LIGHT S/ROOF S/HTR ABS

AUDIO

20A 20A 10A 10A 15A 10A 10A 15A 10A 20A 10A 30A 15A 10A 10A 10A 10A 10A 30A 15A 10A 10A 15A 15A 20A 10A 10A

Ignition Coil, ECM AMP. Multi Gauge Unit B/Up Lamp Air Bag Indicator Air Bag Outside Mirror Defroster Hazard Warning Light Rear Window Wiper Taillight Front Window Wiper A/Conditioner Rear Window Defroster Stop Light Tail Light A/Conditioner ECM, Multi Gauge Unit, TCM Cluster Map Light, Clock, Audio Power Window Tail Gate Open A/Con, A.Q.S Sensor Rear Fog C/Lighter, Outside Mirror Sunroof Seat Warmer ABS. TCS Audio, Clock

6-21

HGK204-E

7. EMISSION CON- TROL SYSTEMS

H010A01GK-AAT EMISSION CONTROL SYSTEM Your Hyundai is equipped with an emission control system to meet all requirements of the U.S. Environmental Protection Agency or Cali- fornia Air Resources Board. There are three emission control systems which are as follows.

1) Crankcase Emission Control System 2) Evaporative Emission Control System 3) Exhaust Emission Control System

In order to ensure the proper function of the emission control systems, it is recommended that you have your car inspected and main- tained by an authorized Hyundai dealer in ac- cordance with the maintenance schedule in this manual.

Caution for Inspection and Maintenance Test (Vehicle with Traction Control System)

o To prevent the vehicle from misfiring during dynamometer testing, disconnect the ABS connector located inside of the wheel guard (driver side).

o For more information, see shop manual

(BR Group, Wheel Speed Sensor).

EMISSION CONTROL SYSTEMS

H010B01A-AAT 1. Crankcase Emission Control

System

The Positive Crankcase Ventilation System is employed to prevent air pollution caused by blow-by gases being emitted from the crank- case. This system supplies fresh filtered air to the crankcase through the air intake hose. Inside the crankcase, the fresh air mixes with blow-by gases, which then pass through the PCV valve and into the induction system.

H010C01S-AAT 2. Evaporative Emission Control (In- cluding ORVR: Onboard Refueling Vapor Recovery) System

The Evaporative Emission Control System is designed to prevent fuel vapors from escaping into the atmosphere. (The ORVR system is designed to allow the vapors from the fuel tank to be loaded into a canister while refueling at the gas station, preventing the escape of fuel vapors into the atmosphere.)

Canister Fuel vapors generated inside the fuel tank are absorbed and stored in the onboard canister. When the engine is running, the fuel vapors absorbed in the canister are drawn into the induction system through the purge control so- lenoid valve.

Purge Control Solenoid Valve (PCSV) The purge control solenoid valve is controlled by the Engine Control Module (ECM); when the engine coolant temperature is low during idling, the PCSV closes so that evaporated fuel is not taken into the engine. After the engine warms- up during ordinary driving, the PCSV opens to introduce evaporated fuel to the engine.

H010D01A-AAT 3. Exhaust Emission Control System The Exhaust Emission Control System is a highly effective system which controls exhaust emissions while maintaining good vehicle per- formance.

H020A01S-AAT CATALYTIC CONVERTER

Catalytic Converter (Federal, California)

Catalytic Converter (California)

SSA7020A

7-1

EMISSION CONTROL SYSTEMS

o Do not touch the catalytic converter or any other part of the exhaust system while the catalytic converter is hot. Shut off the engine, wait for at least one hour before touching the catalytic converter or any other part of the exhaust system. o Remember that your Hyundai dealer is

your best source of assistance.

o Do not stop your Hyundai over any com- bustible material such as grass, paper, leaves or rags. These materials might contact the hot catalytic converter and a fire might result.

All Hyundai vehicles are equipped with one or two monolith type three-way catalytic convert- ers to reduce the carbon monoxide, hydrocar- bons and nitrogen oxides contained in the ex- haust gas. Exhaust gases passing through the catalytic converter cause it to operate at a very high temperature. The introduction of large amounts of unburned gasoline into the exhaust may cause the catalytic converter to overheat and create a fire hazard. This risk may be reduced by observing the following:

WARNING: o Use unleaded fuel only. o Maintain the engine in good operating condition. Extremely high catalytic con- verter temperatures can result from im- proper operation of the electrical, igni- tion or multiport electronic fuel injection. o If your engine stalls, pings, knocks, or is hard to start, have your Hyundai dealer inspect and repair the problem as soon as possible.

o Avoid driving with a very low fuel level. Running out of gasoline may cause the engine to misfire and result in damage to the catalytic converter.

o Avoid idling the engine for periods longer

than 10 minutes.

o The vehicle should not be pushed or pulled to get started. This may cause the catalytic converter to overheat and cre- ate a fire hazard.

7-2

CONSUMER INFORMATION & REPORTING SAFETY DEFECTS

8. CONSUMER

INFORMATION & REPORTING SAFE- TY DEFECTS

I010A01A-AAT VEHICLE IDENTIFICATION NUMBER (VIN)

I030A01GK-AAT RECOMMENDED INFLATION PRES- SURES

1. On the bulkhead between the engine and

passenger compartments.

2. On the left top side of the instrument panel where it can be seen by looking down through the windshield.

3. On the lower side of the center pillar outer

panel.

I010B01A-AAT Engine Number

DOHC

V6

HGK092

The tire label located on the driver side center pillar outer panel gives the tire pressures rec- ommended for your vehicle.

I010B01GK

RIM SIZE

TIRE SIZE

PRESSURE, kPa (PSI)

UP TO 2
PERSONS

UP TO

MAX. LOAD

HGK220A

The engine number is stamped on the engine block as shown in the drawing.

The vehicle identification number (VIN) is the number used in registering your car and in all legal matters pertaining to its ownership, etc. It can be found in three different places on your car:

I020A01A-AAT TIRE INFORMATION The tires supplied on your new Hyundai are chosen to provide the best performance for normal driving.

6.0Jx15
6.5Jx16
7.0Jx17
4Tx16

FRONT 210(30) 210(30) 220(32) 420(60)

REAR 210(30) 210(30) 210(30) 420(60)

FRONT 210(30) 230(33) 240(35) 420(60)

195/65R15
205/55R16
215/45R17
T125/70R16

REAR 210(30) 230(33) 230(33) 420(60) These pressures were chosen to provide the