2005 Hyundai Tucson Owners Manual

F020A02Y-AAT SCHEDULED MAINTENANCE REQUIREMENTS

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

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

o For severe usage maintenance require-

ments, see page 5-6 of this section.

5 VEHICLE MAINTENANCE REQUIREMENTS

SCHEDULED MAINTENANCE

F030A01A-AAT The following maintenance services must be performed to ensure good emission control and performance. Keep receipts for all vehicle emission services to protect your warranty. Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.

F030B02JM-AAT R :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.

No.

DESCRIPTION

KILOMETERS X 1000

MILES X 1000

MONTHS

7.5

12

15

24

12

22.5

30

37.5

45

52.5

36

18

48

24

60

30

72

36

84

42

60

96

48

67.5

75

82.5

90

97.5

105

112.5

120

127.5

135

142.5

150

108

120

132

144

156

168

180

192

204

216

228

240

54

60

66

72

78

84

90

96

102

108

114

120

EMISSION CONTROL ITEMS

ENGINE OIL AND FILTER

FUEL FILTER

FUEL LINES, FUEL HOSES AND CONNECTIONS

VACUUM HOSES

CRANKCASE VENTILATION HOSE

VAPOR HOSE AND FUEL FILLER CAP

AIR CLEANER FILTER

AIR FILTER-CANISTER

SPARK PLUGS (PLATINUM COATED) - 2.0L

SPARK PLUGS (IRIDIUM COATED) - 2.7L

10

VALVE CLEARANCE (2.0L only)

R: 100.000 miles / 120 months

F030C02JM-AAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary 60
96
48

MILES X 1000
KILOMETERS X 1000
MONTHS

22.5
36
18

37.5
60
30

52.5
84
42

DESCRIPTION

7.5
12

15
24
12

30
48
24

45
72
36

No.

GENERAL ITEMS DRIVE BELT

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

See Note (1)

COOLANT TIMING BELT (WHEN REPLACE TIMING BELT AND INSPECT WATER PUMP : 2.7L) (See Note (2)- 2.0 L) MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID BRAKE FLUID BRAKE HOSES AND LINES REAR BRAKE DRUMS/LININGS, PARKING BRAKE BRAKE PADS, CALIPERS AND ROTORS EXHAUST PIPE AND MUFFLER SUSPENSION MOUNTING BOLTS STEERING GEAR BOX, LINKAGE & BOOTS / LOWER ARM BALL JOINT POWER STEERING PUMP, BELT AND HOSES DRIVESHAFTS AND BOOTS AIR CONDITIONING REFRIGERANT TRANSFER CASE OIL (4WD) REAR AXLE OIL (4WD) PROPELLAR SHAFT CLEAN, BOLT RETIGHTEN (4WD) AIR CONDITIONER FILTER

10
11
12

13
14
15
16
17
18
19

Note : (1) When replace drive belt and inspect water pump.

(2) For every 48 months or 37,200 miles (60,000 km), whichever occurs first : "I" For every 72 months or 56,000 miles (90,000 km), whichever occurs first : "R" Inspect every 25,000 miles (40,000 km)and replace every 62,000 miles (100,000 km). lnspect every 25,000 miles (40,000 km)

(3) (4) (5) For every 12 months or 12,500 miles (20,000 km) whichever occurs first :"R"

VEHICLE MAINTENANCE REQUIREMENTS

67.5
108
54

75
120
60

82.5
132
66

90
144
72

97.5
156
78

105
168
84

112.5
180
90

120
192
96

127.5
204
102

135
216
108

142.5
228
114

150
240
120

See Note (3) See Note (4) See Note (5)

5 VEHICLE MAINTENANCE REQUIREMENTS

MAINTENANCE UNDER SEVERE USAGE CONDITIONS

F040A02JM-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

EVERY 3,000 MILES (4,800 KM) OR 3 MONTHS INSPECT EVERY 20,000MILES (32,200 KM) REPLACE EVERY 40,000MILES (64,400 KM) MORE FREQUENTLY MORE FREQUENTLY MORE FREQUENTLY

I/R

ENGINE OIL AND FILTER TIMING BELT (WHEN REPLA CE TIMING BELT and INSPECT WATER PUMP : 2.7L) AIR CLEANER FILTER SPARK PLUGS BRAKE PADS, CALIPERS AND ROTORS REAR BRAKE DRUMS/LININGS/PADS, PARKING BRAKE STEERING GEAR BOX, LINKAGE & BOOTS/ LOWER ARM BALL JOINT DRIVESHAFTS AND BOOTS MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID AIR CONDITIONER FILTER TRANSFER CASE OIL (4WD) *1
REAR AXLE OIL (4WD) *1
*1. Transfer case Oil ended Rear Axle Oil should be changed anytime they have been submerged in water. SEVERE DRIVING CONDITIONS A - Repeatly driving short distance of less than 5miles(8km) in normal tempera

MORE FREQUENTLY

MORE FREQUENTLY 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 EVERY 25,000 MILES (40,000 KM) EVERY 50,000 MILES (80,000 KM)

DRIVING

CONDITION

A, B, C, F, G, H, I, K

C, D, F, G

C, E B, H C, D, G, H

C, D, G, H

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

ture or less than 10miles(16km) in freezing temperature

B - Extensive engine idling or low speed driving for long distances C - Driving on rough, dusty, muddy, unpaved, graveled or salt-spread roads D - Driving in areas using salt or other corrosive materials or in very

cold weather

E - Driving in sandy areas F - Driving in heavy traffic area over 90°F(32°C) G- Driving on uphill, downhill, or mountain road H - Towing a Trailer, or using a camper, or roof rack I - Driving as a patrol car, taxi, other commercial use or vehicle towing J - Driving over 100 MPH(170 Km/h) K - Frequently driving in stop-and-go conditions

EXPLANATION OF SCHEDULED MAINTENANCE ITEMS

VEHICLE MAINTENANCE REQUIREMENTS

F060A01A-AAT

F060M01A-AAT o Engine Oil and Filter

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

F060C01A-AAT o Fuel Filter

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

F060B01A-AAT o Drive Belts

F060F01O-AAT o Vacuum Hoses

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.

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

tions

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

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.

5 VEHICLE MAINTENANCE REQUIREMENTS

F065F01O-AAT o Crankcase Ventilation Hose

F060H01A-AAT o Air Cleaner Filter

F070D01A-AAT o Manual Transaxle Oil

Inspect the surface of hose for evidence of heat and/or mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions, and excessive swelling indicate deterioration. Par- ticular attention should be paid to examine that hose surface nearest to high heat sources, such as the exhaust manifold. Inspect the hose routing to assure that the hose does not come in contact with any heat source, sharp edges or moving component which might cause heat damage or mechanical wear. In- spect all hose connections, such as clamps and couplings, to make sure they are secure, and that no leaks are present. Hose 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.

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

Inspect the manual transaxle oil according to the maintenance schedule.

F060J01A-AAT o Spark Plugs

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

F060E01A-AAT o Timing Belt

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

F070C01A-AAT o Coolant

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

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

F070E04A-AAT o Automatic Transaxle Fluid and Filter

The fluid level should be in the "HOT" range of the dipstick, after the engine and transaxle are at normal operating temperature. Check the automatic transaxle fluid level with the engine running and the transaxle in neutral, with the parking brake properly applied. Use HYUNDAI GENUINE ATF SP III, DIAMOND ATF SP III, SK ATF SP III or other brands approved by Hyundai Motor Co., when adding or changing fluid. Using the wrong ATF may result in damage to the ATM.

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.

VEHICLE MAINTENANCE REQUIREMENTS

F070G02A-AAT o Brake Fluid

F070K01A-AAT o Exhaust Pipe and Muffler

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

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

F070H01O-AAT o Rear Brake Discs and Linings/

F070L01A-AAT o Suspension Mounting Bolts

Parking Brake

Check the rear brake discs 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.

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. Replace or adjust it if necessary.

F070P01A-AAT o Driveshafts and Boots

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

F070Q01A-AAT o Air Conditioning Refrigerant

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

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 ................ 6-8
Spark Plugs ................................................................ 6-10
Changing the Air Cleaner Filter ................................... 6-11
Checking the Transaxle Oil (Manual) ......................... 6-13
Checking the Transaxle Fluid (Automatic) .................. 6-14
Checking the Brakes .................................................. 6-15
Checking the Clutch Fluid ........................................... 6-16
Air Conditioning Care .................................................. 6-17
Changing the Air Conditioner Filter ............................. 6-18
Checking the Free-play ............................................... 6-19
Checking Drive Belts .................................................. 6-21
Checking and Replacing Fuses .................................. 6-21
Checking the Battery .................................................. 6-23
Power Steering Fluid Level ......................................... 6-24
Replacement of Light Bulbs ........................................ 6-26
Bulb Wattage ............................................................... 6-34
Fuse Panel Description ............................................... 6-35

6 DO-IT-YOURSELF MAINTENANCE

ENGINE COMPARTMENT

G010A01JM-GAT (2.7 Gasoline)

CAUTION:

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

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

5. Windshield washer fluid reservoir 6. Engine oil level dipstick 7. Coolant reservoir cap 8. Engine oil filler cap

9. Automatic transaxle fluid level dipstick (Ve-

hicle with Automatic Transaxle)

10. Radiator cap 11. Battery

G010A01JM

G010B01JM-AAT (2.0 Gasoline)

DO-IT-YOURSELF MAINTENANCE

CAUTION:

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

1. Power steering fluid reservoir 2. Engine oil filler cap 3. Brake & Clutch fluid reservoir 4. Air cleaner

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

9. Automatic transaxle fluid level dipstick

(Vehicle with Automatic Transaxle)

10. Radiator cap 11. Battery

G010B01JM

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 correctly, 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.

G030B01O-AAT Recommended Oil

NOTE: o For good fuel economy, SAE 5W-20 (5W- 30), ILSAC GF-3 engine oil is preferred regardless of regional option and en- gine variation.

o If SAE 5W-20, ILSAC GF-3 engine oil is not available, secondary recommended engine oil for corresponding tempera- ture range can be used.

G030B01JM-U The engine oil quality should meet the following classification.

API SJ, SL or ABOVE, ILSAC GF-3 or ABOVE

DO-IT-YOURSELF MAINTENANCE

G030C01JM-AAT To Check the Oil Level

DOHC

V6

G030C01JM 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 five minutes , then remove the dipstick, wipe it off, fully reinsert the dipstick and withdraw it again. Then note the highest level the oil has reached on the dipstick. It should be between the upper ("FULL") and lower ("LOW") range.

WARNING:

Be very careful not to touch the radiator hose when checking the engine oil as it may be hot enough to burn you.

6 DO-IT-YOURSELF MAINTENANCE

G030D01JM-AAT Adding Oil

DOHC

V6

G030D01JM If the oil level is close to or below the "L" mark, add oil until it reaches the "F" mark. To add oil:

WARNING:

Be very careful not to touch the radiator hose when adding the engine oil as it may be hot enough to burn you.

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 "F" and "L" marks is equal to about 1 quart of oil.

CHANGING THE OIL AND FILTER

G040A01JM-AAT

DOHC

V6

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).

DO-IT-YOURSELF MAINTENANCE

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.

2. Open the hood and remove the engine oil

6.

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.

WARNING:

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

Install a new oil filter in accordance with the instructions on the carton or on the filter itself. Do not over-tighten. (Tightening torque : 1.2 ~ 1.6 kgf.m) Be sure that the mounting surface on the engine is clean and that the old gasket is removed completely. Lubricate the new gasket on the filter with clean engine oil before installation.

7. Remove the engine oil level dipstick. 8. Refill the crankcase with the recommended engine oil. Refer to the specification in chap- ter 9 for engine oil capacity.

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

Oil pan drain plug tightening torque: 3.5 ~ 4.5 kgf.m (2.7L) 4.0 ~ 4.5 kgf.m (2.0L)

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.

CAUTION:

Slowly pour the recommended oil using by a funnel. Do not overfill! Engine damage may occur if overfilled.

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

is leaking from the drain plug or oil filter.

10.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.

6 DO-IT-YOURSELF MAINTENANCE

CHECKING AND CHANGING THE ENGINE COOLANT

G050A01A-AAT

G050B01A-AAT Recommended Engine Coolant

G050C01A-AAT To Check the Coolant Level

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.

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

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

Antifreeze solution

35% 40% 50% 60%

Water

65% 60% 50% 40%

G050C01JM

The coolant level can be seen on the side of the plastic coolant reservoir. The level of the cool- ant should be between the "L" and "F" lines on the reservoir when the engine is cool. If the level is below the "L" mark, add engine coolant to bring it up between "L" and "F". If the level is low, inspect for coolant leaks and recheck the fluid level frequently. If the level drops again, visit your Hyundai dealer for an inspection and diagnosis of the reason.

G050D02A-AAT To Change the Engine Coolant

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

CAUTION:

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

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

HJM5034

2. 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.

3. 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. 4. 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.

5. Fill the radiator with clean demineralized or distilled water. Continue to add clean dem- ineralized or distilled water in small quantities until the fluid level stays up in the radiator neck.

DO-IT-YOURSELF MAINTENANCE

G050D01JM

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

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

WARNING:

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

6 DO-IT-YOURSELF MAINTENANCE 10

SPARK PLUGS

G060B01JM-AAT Replacing the Spark Plugs

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

G060C01JM-AAT Changing the Spark Plugs

Recommended Spark Plugs: TYPE

REMARK

2.7

(Iridium Coated)

IFR5G-11 (NGK)

2.0L

PFR5N-11(NGK)

(Platinum Coated)

RC10YPB4 (CHAMPION)

NOTE: o When replacing the spark plug, genuine Hyundai replacement parts are recom- mended.

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

o Do not clean or regap spark plugs.

G060C01JM

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

1. Remove the center cover (2.0L) on the

engine rocker cover.

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

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

DO-IT-YOURSELF MAINTENANCE

CHANGING THE AIR CLEANER FILTER G070A01E-AAT

11

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

G060C02JM

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.

G060C03JM

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

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

HJM5038

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 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.

6 DO-IT-YOURSELF MAINTENANCE 12

WINDSHIELD WIPER BLADES

FILLING THE WASHER RESERVOIR

G080A02A-AAT

G090A01JM-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 dam- age the washer fluid pump.

G090A01JM

The washer fluid reservoir supplies fluid to the front and rear washer systems. 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 3.59
U.S. quarts (3.4 Liters).

HJM5032
The wiper blades should be carefully inspected from time to time and cleaned to remove accu- mulations of road film or other debris. To clean the wiper blades and arms, use a clean sponge or cloth with a mild soap or detergent and water. If the wipers continue to streak or smear the glass, replace them with genuine Hyundai re- placement parts or their equivalent.

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

13

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

CHECKING THE TRANSAXLE OIL (MANUAL)

G100A02JM-AAT

Filler plug

Drain plug

HJM5009
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/85 (API GL-4) or EQUIVALENT in the manual transaxle.

Manual Transaxle Oil Capacity

The oil capacity of the manual transaxle is 2.2
U.S. quarts (2.1 liters).

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.

G100B02A-AAT To Check the Manual Transaxle Fluid Level

G100B01L

6 DO-IT-YOURSELF MAINTENANCE 14

CHECKING THE TRANSAXLE FLUID (AUTOMATIC)

G110A01E-AAT 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.

G110B04A-AAT Recommended Fluid

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

CAUTION:

Use of aftermarket ATF additives may cause damage to the automatic transaxle. Only use HYUNDAI GENUINE ATF SP III, DIA- MOND ATF SP III, SK ATF SP III or other brands approved by Hyundai Motor Co., If you are having your vehicle serviced at a facility other than a Hyundai dealer, verify ATF is used for your vehicle.

G110C01JM-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 temperature. This means that the engine, radiator, exhaust system etc., are very hot so you should exercise great care not to burn yourself during this procedure.

G110D02O-AAT To Check the Transaxle Fluid Level

HJM3018
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.

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.

Fluid level should be within "HOT" range

DO-IT-YOURSELF MAINTENANCE

CHECKING THE BRAKES

15

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.

HJM5011
2. Remove the transaxle dipstick, wipe it clean, reinsert the dipstick as far as it will go, then remove it again. Now check the fluid level on the dipstick. It should be in the "HOT" range on the dipstick. If the transaxle fluid level is low, use a funnel to add transaxle fluid through the dipstick tube until the level reaches the "HOT" range. Do not overfill.

3.

WARNING:

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

HJM5044

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

CHECKING THE CLUTCH FLUID

G120C02A-AAT Recommended Brake Fluid

G120E02A-AAT Adding Brake Fluid

G130A01A-AAT To Check the Clutch 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

HJM5007

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.

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.

HJM5007

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

G140A01A-AAT Keeping the Condenser Clean

G140C01A-AAT Lubrication

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.

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 fans.

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.

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 refrig- erant level may damage the compressor.

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.

G140D02A-AAT Checking the Compressor Drive Belt

DOHC CVVT

V6

Water Pump Pulley

0.2~0.24 in. (5~6 mm)

Power steering

Auto tensioner

Alternator

Alternator Pulley

Crankshaft Pulley

COMP

Eng.pulley

G190A01GK

6 DO-IT-YOURSELF MAINTENANCE 18

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 the belt is too loose, have it adjusted by your Hyundai dealer.

CHANGING THE AIR CONDITIONER FILTER

B145A02JM-GAT (For Evaporator and Blower Unit) (If Installed)

The air conditioner filter is located in front of the evaporator unit behind the glove box. It helps to decrease the amount of pollutants entering the car.

1. Open the glove box and remove the support

strap through the hole.

HJM2133

HJM2136
2. Lower the glove box down completely by pushing the both sides of the glove box inward.

HJM2134

3. Remove the air conditioner filter cover by

pressing both side's clips.

G150A01A-AAT STEERING WHEEL

DO-IT-YOURSELF MAINTENANCE

CHECKING THE FREE-PLAY

19

4. Remove the air conditioner filter by lifting it. 5. Installation is the reverse order of disassem- bly.

HJM2135

CAUTION:

Be sure to install the air conditioner filter in the direction of the arrow sign. Otherwise, noise or filter damage may result.

B145A01JM

1.18 in. (30 mm)

G150A01JM

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.

6 DO-IT-YOURSELF MAINTENANCE 20

G160A01A-AAT CLUTCH PEDAL FREE PLAY

G170A01A-AAT BRAKE PEDAL FREE PLAY

CHECKING BRAKE PEDAL CLEARANCE

G180A01A-AAT

0.24 ~ 0.51 in. (6 ~ 13 mm)

0.12 ~ 0.31 in. (3 ~ 8 mm)

2.95 in. (75 mm)

G160A01HR 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.

G160A01HR

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 above. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired 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 AND REPLACING FUSES G200A03A-AAT Replacing a Fusible Link

DO-IT-YOURSELF MAINTENANCE

21

CHECKING DRIVE BELTS

G190A01A-AAT

DOHC CVVT

V6

Water Pump Pulley

0.2~0.24 in. (5~6 mm)

Power steering

Auto tensioner

Alternator

Alternator 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.

Open- Replace

Good

G200A01JM

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 in the engine compartement 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.

G200B01JM-AAT Replacing Accessory Fuses

HJM4002
The fuse box for the lights and other electrical accessories will be found on the left side of crash pad. 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

6 DO-IT-YOURSELF MAINTENANCE 22

accessories stop working, a blown (open) fuse could be the reason. If the fuse has opened, you will see that the metal strip inside the fuse has melted 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 opened.

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:

An open fuse indicates that there is a prob- lem in the electrical circuit. If you replace 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 replace a fuse with anything except a fuse with the same or a lower amperage rating. A higher capac- ity fuse could cause damage and create a fire hazard.

NOTE: See page 6-35 for the fuse panel descrip- tions.

Good

Open-Replace

G200B02L

G200B01JM

CHECKING THE BATTERY

G210A01A-AAT

HJM5008

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:

DO-IT-YOURSELF MAINTENANCE

23

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