2004 Hyundai Tiburon Owners Manual

MAINTENANCE UNDER SEVERE USAGE CONDITIONS

F040A01GK-AAT 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 RACK, LINKAGE & BOOTS/ LOWER ARM BALL JOINT DRIVESHAFTS AND BOOTS MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID AIR CONDITIONER FILTER (FOR BLOWER UNIT)

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) 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 as a patrol car, taxi, other commercial use car or vehicle towing

EXPLANATION OF SCHEDULED MAINTENANCE ITEMS

VEHICLE MAINTENANCE REQUIREMENTS

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.

F060D01A-AAT o Fuel Lines, Fuel Hoses and

Connections

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

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.

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.

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.

F060N02E-AAT o Valve Clearance

Inspect excessive valve noise and/or engine vibration and adjust if necessary. A qualified technician should perform the operation.

5 VEHICLE MAINTENANCE REQUIREMENTS

F060B02A-AAT o Drive Belts

F070D01A-AAT o Manual transaxle oil

F070G02A-AAT o Brake Fluid

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.

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.

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.

F070C01A-AAT o Coolant

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

F060E01A-AAT o Timing belt

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

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 immedi- ately.

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.

VEHICLE MAINTENANCE REQUIREMENTS

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.

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.

F070L01A-AAT o Suspension Mounting Bolts

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

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.

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.

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.

Do-It-Yourself Maintenance

Engine Compartment .................................................... 6-2
General Checks ............................................................ 6-4
Checking the Engine Oil ............................................... 6-5
Changing the Oil and Filter ............................................ 6-6
Checking and Changing the Engine Coolant ................ 6-7
Spark Plugs .................................................................. 6-9
Changing the Air Cleaner Filter ................................... 6-11
Checking the Transaxle Oil (manual) ......................... 6-12
Checking the Transaxle Fluid (Automatic) .................. 6-13
Checking the Brakes .................................................. 6-15
Checking the Clutch Fluid ........................................... 6-16
Air Conditioning Care .................................................. 6-17
Checking Drive Belts .................................................. 6-20
Checking and Replacing Fuses .................................. 6-21
Checking the Battery .................................................. 6-22
Power Steering Fluid Level ......................................... 6-24
Replacement of Light Bulbs ........................................ 6-26
Bulb Wattage ............................................................... 6-31

6 DO-IT-YOURSELF MAINTENANCE

ENGINE COMPARTMENT

G010A01GK-AAT (2.0 DOHC CVVT)

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.

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

HGK059-1

G010B01GK-GAT (2.7 V6)

DO-IT-YOURSELF MAINTENANCE

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.

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

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

HGK209-1

6 DO-IT-YOURSELF MAINTENANCE GENERAL CHECKS

G020A01A-AAT Engine Compartment

G020B01A-AAT Vehicle Exterior

G020C01A-AAT Vehicle Interior

The following should be checked regularly:

The following should be checked monthly:

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

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.

CHECKING THE ENGINE OIL

G030A01A-AAT 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.

G030B02A-AAT Recommended Oil 2.7 V6

G030B01A SH, SG or SG/CD (API) multi-grade and fuel efficient oil is recommended.

DO-IT-YOURSELF MAINTENANCE

2.0L DOHC CVVT

G030C02A-AAT To Check the Oil Level

DOHC CVVT

V6

G030B02A SH (API) or GF-1 (ILSAC) and ABOVE multi- grade and fuel efficient oil is recommended.

HGK210
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 5 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 ("FULL") and lower ("LOW") range.

6 DO-IT-YOURSELF MAINTENANCE

G030D01A-AAT Adding Oil

DOHC CVVT

V6

CHANGING THE OIL AND FILTER

G040A02GK-AAT

DOHC CVVT

V6

2. Open the hood and remove the engine oil

filler cap.

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.

HGK211
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-

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

clockwise.

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.

WARNING:

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

G040A01GK 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).

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)

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)

6.

CHECKING AND CHANGING THE ENGINE COOLANT

G050A01A-AAT

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.

DO-IT-YOURSELF MAINTENANCE

G050B01A-AAT Recommended Engine Coolant

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%

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.

PROPOSITION 65 WARNING: Used engine oil may cause irritation or cancer of the skin if left in contact with the skin for prolonged periods of time. Used engine oil contains chemicals that have caused cancer in laboratory animals. Al- ways protect your skin by washing your hands thoroughly with soap and warm water as soon as possible after handling used oil.

6 DO-IT-YOURSELF MAINTENANCE

G050C01A-AAT To Check the Coolant Level

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.

HGK187
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 frequently. If the level drops again, visit your Hyundai dealer for an inspection and diagnosis of the reason.

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.

G050D03E 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.

!

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.

DO-IT-YOURSELF MAINTENANCE

SPARK PLUGS

G060A01GK-AAT

DOHC CVVT

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.

G050D04E 5. Start the engine, top off the radiator with water and then add coolant to the reservoir until the level is between "LOW" and "FULL". 6. Replace the radiator and reservoir caps and check to be sure the drain cocks are fully closed and not leaking.

6 DO-IT-YOURSELF MAINTENANCE 10

G060B02GK-AAT Replacing the Spark Plugs

G060C02GK-AET Changing 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: When replacing the spark plugs, genuine Hyundai replacement parts are recom- mended.

Recommended Spark Plugs:

Type

RC10PYPB4(CHAMPION) PFR5N-11(NGK)

HGK256
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 engine rocker cover.

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

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.

HGK257

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.

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.

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.

HGK258

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.

CHANGING THE AIR CLEANER FILTER G070A01GK-AAT

DO-IT-YOURSELF MAINTENANCE

WINDSHIELD WIPER BLADES

11

G080A02A-AAT

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.

o When removing the air cleaner filter, be careful that dust or dirt does not enter the air intake. These may result in dam- age to the air cleaner filter.

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 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.

6 DO-IT-YOURSELF MAINTENANCE 12

FILLING THE WASHER RESERVOIR

G090A01A-AAT

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 should not be operated if the washer reservoir is empty. This can damage the washer fluid pump.

HGK217
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 inclement weather or whenever the washer system is in more frequent use. The capacity of the washer reservoir is 3.2 U.S. quarts (3.0 Liters).

CHECKING THE TRANSAXLE OIL

G100A02GK-AAT (MANUAL)

Filler plug

Drain plug

G100A01GK 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: 5 speed: 2.27 U.S. quarts (2.15L) 6 speed: 2.32 U.S. quarts (2.2L)

! 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.

G100B01A-AAT To Check the Manual Transaxle Fluid Level

Park the car on level ground with the engine off.

G100B01L

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 fingers and then tighten securely with the wrench.

DO-IT-YOURSELF MAINTENANCE

13

G110A01E-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.

NOTE: Automatic transaxle fluid is basically red color. As driving distance increases, the fluid color turns darkish red gradually. It is a normal condition and you should not judge the need to replace based upon the changing color. You must replace the automatic transaxle fluid in accordance with 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.

6 DO-IT-YOURSELF MAINTENANCE 14

G110C02Y-AAT Transaxle Fluid Capacity

G110D02Y-AAT To Check the Transaxle Fluid Level

DOHC CVVT

V6

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 temperature. This means that the engine, radiator, exhaust system etc., are very hot. Exercise great care not to burn yourself during this procedure.

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.

HGK212
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.

CHECKING THE BRAKES

G120A01A-AAT

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.

DO-IT-YOURSELF MAINTENANCE

15

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.

Fluid level should be within this range

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.

HGK249

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.

6 DO-IT-YOURSELF MAINTENANCE 16

G120E02A-AAT Adding Brake 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.

CHECKING THE CLUTCH FLUID

G130A01S-AAT To Check the Clutch Fluid

HGK215

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.

HGK216
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.

AIR CONDITIONING CARE

DO-IT-YOURSELF MAINTENANCE

17

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.

G140A01A-AAT Keeping the Condenser Clean

The air conditioning condenser (and engine radiator) should be checked periodically for accumulation of dirt, dead insects, leaves, etc. These can interfere with maximum cooling ef- ficiency. 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.

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 imme- diately.

CAUTION:

Running the air conditioning system for extended periods of time with a low refrig- erant 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.

6 DO-IT-YOURSELF MAINTENANCE 18

G140D01A-AAT Checking the Compressor Drive Belt

DOHC CVVT

V6

A/C

Auto tensioner

0.315 in. (8 mm)

CHANGING THE AIR CONDITIONER FILTER B760B01GK-AAT (If installed)

Crank pulley

Tension pulley

Eng.pulley COMP G140D01GK When the air conditioning is being used regu- larly, 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.

HGK250
1. Remove the mounting screws on the down-

side of the glove box.

HGK251
2. Open the glove box and remove the mount- ing screws on the upside of the glove box.

3. Remove the filter cover.

HGK253

CHECKING THE FREE-PLAY

G150A01A-AAT Steering Wheel

G160A01A-AAT Clutch Pedal

DO-IT-YOURSELF MAINTENANCE

19

0.24 ~ 0.51 in. (6~13 mm)

1.18 in. (30 mm)

HGK218
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.

G160A01E 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 illus- tration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.

HGK254
4. Replace the air conditioner filter with a new

5.

one. Installation is the reverse order of disassem- bly.

CAUTION:

Be sure to install the air conditioner filter in the direction of the arrow sign. Otherwise, it may cause noise or deterioration.

6 DO-IT-YOURSELF MAINTENANCE 20

G170A01A-AAT Brake Pedal

G180A01A-AAT CHECKING BRAKE PEDAL CLEARANCE

0.12~0.31 in. (3~8 mm)

1.78 in. (45.1 mm)

HXGS508
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 inspected by your Hyundai dealer and adjusted or re- paired if necessary.

G180A01L 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.

CHECKING DRIVE BELTS

G190A01A-AAT

DOHC CVVT

V6

Water Pump Pulley

0.2~0.24 in. (5.1~6 mm)

Power steering

Auto tensioner

Generator

Generator Pulley

Crankshaft Pulley

COMP

Eng.pulley

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 replaced, the new belt should be adjusted again after two or three weeks to eliminate slack resulting from initial stretching after use.

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.

CHECKING AND REPLACING FUSES G200A01A-AAT Replacing a Fusible Link

Bad

Good

G200A01E A fusible link will melt if the electrical circuits from the battery are ever overloaded, thus prevent- ing 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.

DO-IT-YOURSELF MAINTENANCE

21

G200B02A-AAT Replacing Accessory Fuse

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:

6 DO-IT-YOURSELF MAINTENANCE 22

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.

HXDFL1026-1
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.

Good

Burned out

G200B02L

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 serious 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 6-36 for the fuse panel descrip- tions.

CHECKING THE BATTERY

G210A01A-AAT

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 solution 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 ob- serve these warnings to prevent injuries from occurring: o Charge batteries only in a well ventilated

o Do not permit flames, sparks or smoking in

area.

the area.

o Keep children away from the area.

DO-IT-YOURSELF MAINTENANCE

CHECKING ELECTRIC COOLING FANS G220A01A-AAT

23

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.

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 house- hold baking soda and warm water. After the battery terminals are dry, cover them with a light coating 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. Batteries also contain other chemicals known to the state of California to cause cancer. Wash hands after handling.

6 DO-IT-YOURSELF MAINTENANCE 24

POWER STEERING FLUID LEVEL

G220B01A-AAT Checking Engine Cooling Fan

G230A03A-AAT

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.

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 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.

HEADLIGHT AIMING ADJUSTMENT

G290A02GK-AAT Low Beam

Vertical aiming

DO-IT-YOURSELF MAINTENANCE

25

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. 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.

G290B01GK-AAT Adjustment After Headlight Assembly Replacement

0.827 in. (21 mm)

Vertical line

Horizontal line

"P"

G290A03GK Before performing aiming adjustment, make sure of the following.

1. Keep all tires inflated to the correct pressure. 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.

WARNING:

Horizontal aiming should be adjusted by an authorized Hyundai Dealer.

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 an 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 illustration. 2. Dotted lines in the illustration show the center

of headlights.

6 DO-IT-YOURSELF MAINTENANCE 26

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)

REPLACEMENT OF LIGHT BULBS

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

See page 6-35 for the wattage description.

G270A01GK-AAT Headlight and Front Turn Signal Light

1. Allow the bulb to cool. Wear eye protection. 2. Open the engine hood. 3. Always grasp the bulb by its plastic base,

avoid touching the glass.

CAUTION:

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

HGK823
4. Disconnect the power cord from the bulb

base in the back of the headlight.

DO-IT-YOURSELF MAINTENANCE

27

HGK827

8. Remove the protective cap from the re- placement bulb and install the new bulb by matching the plastic base with the headlight hole. Reattach the bulb spring and recon- nect the connector.

9. Use the protective cap and carton to prompt-

ly dispose of the old bulb.

10.Check for proper headlight aim.

6. Disconnect the connector from the bulb

base in the back of the headlight.

HGK824
5. Turn the plastic cover counterclockwise

and remove it.

HGK826
7. Push the bulb spring to remove the headlight

bulb.

HGK825

6 DO-IT-YOURSELF MAINTENANCE 28

HGK836
11.To replace the front turn signal light bulb, remove from the bulb holder and install the new bulb.

G270B01GK-GAT Rear Combination Light (Without woofer speaker)

(1)

(4)

(3)

(2)

G270A03O

1. Open the tail gate.

HGK837

WARNING:

This halogen bulb contains gas under pres- sure and if impacted could shatter, result- ing in flying fragments. Always wear eye protection when servicing the bulb. Protect the bulb against abrasions or scratches and against liquids when lighted. Turn the bulb on only when installing in a headlight. Replace the headlight if damaged or cracked. Keep the bulb out of the reach of children and dispose of the used bulb with care.

3. Remove the nut (8mm) with a spanner.

DO-IT-YOURSELF MAINTENANCE

29

(4)

(1)

(2)

(3)

HGK845
2. To remove the cover of the rear luggage trim, turn the knob by hand to the counterclock- wise.

HGK847
4. To detach the rear combination light hit it

strongly by hand.

HGK839
5. To replace the rear combination light (stop/ tail light, turn signal light, back-up light, side mark light), take it out from the bulb holder by turning it counterclockwise.

(1) Stop/Tail light (2) Back-up light (3) Turn signal light (4) Side mark light

6.

Install the new bulb.

HGK846

6 DO-IT-YOURSELF MAINTENANCE 30

G275B01GK-GAT Rear Combination Light (With woofer speaker)

(1)

(4)

(3)

(2)

1. Open the tail gate.

HGK837

2. Take off the luggage board.

HGK842

HGK843
3. Extract the mounting screws (10mm) around

the woofer speaker with a spaner.

HGK844
4. Disconnect the power cord from the woofer

speaker.

DO-IT-YOURSELF MAINTENANCE

31

(4)

(1)

(2)

(3)

HGK839
8. To replace the rear combination light (stop/ tail light, turn signal light, back-up light, side mark light), take it out from the bulb holder by turning it counterclockwise.

(1) Stop/Tail light (2) Back-up light (3) Turn signal light (4) Side mark light

9.

Install the new bulb.

HGK845
5. To remove the cover of the rear luggae trim, turn the knob by hand to the counterclock- wise.

6. Remove the nut (8mm) with a spaner.

HGK846

HGK847
7. To detach the rear combination light hit it

strongly by hand.

6 DO-IT-YOURSELF MAINTENANCE 32

G270C01GK-AAT Luggage Compartment Light

G270G01GK-AAT Map Light

HGK830

3. Disconnect the power cord.

HGK840

1. Open the tail gate. 2. Remove the cover with a flat-head screw-

driver.

HGK828
1. Remove the cover with a flat-head screw-

driver.

4. Replace with a new bulb.

HTB284

G270H01GK-GAT Glove Box Illuminated Light

DO-IT-YOURSELF MAINTENANCE

33

2. Replace with a new bulb.

HGK829

HGK250
1. Remove the mounting screws on the down-

side of the glove box.

HGK251
2. Open the glove box and remove the mount- ing screws on the upside of the glove box.

6 DO-IT-YOURSELF MAINTENANCE 34

HGK848
3. Remove the glove box by pulling strongly.

CAUTION:

Be careful not to damage the glove box when pulling the glove box.

Power Cord

Clip

4. Disconnect the power cord. 5. Remove the glove box illuminated light by

pushing the clip.

6. Replace with a new bulb.

HGK841

HTB284

BULB WATTAGE

G280A02GK-AAT

(High)

(Low)

DO-IT-YOURSELF MAINTENANCE

35

11 12

13

10

No.

Part Name

Wattage

No.

Part Name

Head Light (High/Low)

Map Light

Front Position Light

Front Fog Light (If installed)

Front Turn Signal Light/ Front Side Marker

Front Door Edge Warning Light

Luggage Compartment Light

55/55

10

51

28/8

10

11

12

13

High Mounted

Without spoiler

Stop Light

Rear

With spoiler

Rear Side-Marker

Combination

Turn Signal Light

Stop/Tail Light

Back-up Light

License Plate Light

HGK035A

Wattage

2.4 (LED)

3.5 (LED)

27

27/8

27

6 DO-IT-YOURSELF MAINTENANCE 36

FUSE PANEL DESCRIPTION

G200C01GK-GAT Engine Compartment

DESCRIPTION

FUSERATING

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)

120A 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