brake Hyundai Coupe 2004 Service Manual

DO-IT-YOURSELF MAINTENANCE
6-12 G110D02Y-AAT
To Check the Transaxle Fluid Level
HGK174
Park the car on level ground with the parking brake engaged. When the transaxle fluid levelis checked, the transaxle fluid should be atnormal operating temperature and the engineidling.
G110C02Y-GAT
Transaxle Fluid Capacity
The fluid capacity of the automatic transaxle is 7.8 liters (8.2 U.S. quarts). WARNING: The transaxle fluid level should be checked when the engine is at normal operating tem-perature. This means that the engine, radia-tor, exhaust system etc., are very hot. Exer-cise great care not to burn yourself duringthis procedure.
G100B02A-AAT
To Check the Manual Transaxle Fluid Level
SSA6100B
Park the car on level ground with the engine off.
1. Using a wrench of the correct size, loosen the oil filler plug by turning it counterclock- wise and remove it with your fingers.
2. Use your finger or suitable tool to feel inside the hole. The oil level should be at its bottomedge. If it is not, check for leaks beforeadding oil. To refill the transaxle or bring theoil level up,add oil slowly until it reaches theproper level. Do not overfill.
3. Replace the plug and washer, screw it in with your fingers and then tighten securelywith the wrench. G110A02A-AAT CHECKING THE TRANSAXLE FLUID (AUTOMATIC) Transaxle fluid in the automatic transaxle should be checked at those intervals specified in thevehicle maintenance schedule in Section 5. NOTE: Basically automatic transaxle fluid is red color. As driving distance increases, thefluid color turns darkish red gradually. It isnormal condition and you should not usefluid color as a criterion for replacing thetransaxle fluid. You must replace the automatic transaxle fluid in accordance with intervals specifiedin the vehicle maintenances schedule insection 5. G110B03A-AAT
Recommended Fluid
Your Hyundai automatic transaxle is specially
designed to operate with DIAMOND ATF SP-III or SK ATF SP-III. Damage caused by anonspecified fluid is not covered by your newvehicle limited warranty.

DO-IT-YOURSELF MAINTENANCE 6-13
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" — andthen return to "N" or "P". With the engine stillidling:
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, thenremove it again. Now check the fluid level onthe dipstick. It should be in the "HOT" rangeon the dipstick.
3. If the transaxle fluid level is low, use a funnel to add transaxle fluid through the dipsticktube until the level reaches the "HOT" range.Do not overfill. WARNING: The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper- ate even when the engine is not running.Use extreme caution when working near theblades of the cooling fan, so that you are notinjured by a rotating fan blade. As the en-gine coolant temperature decreases, the fanwill automatically shut off. This is a normalcondition. Fluid level should be within this range
HGK249
ÎÎ
DOHC V6
HGK212
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 thecontainer. G120A01A-AAT
CHECKING THE BRAKES
CAUTION: Because brakes are essential to the safe
operation of the car, it is suggested that they be checked and inspected by yourHyundai dealer. The brakes should bechecked and inspected for wear at thoseintervals specified in the vehicle mainte-nance schedule in Section 5.
G120B01A-AAT
Checking the Brake Fluid Level WARNING: Use caution when handling brake fluid. It
can damage your vision if it gets into your eyes. It will also damage your vehicle's paintif spilled on it and not removed immediately.

DO-IT-YOURSELF MAINTENANCE
6-14 G130B02A-AAT
To Replace the Fluid
Recommended brake fluid conforming to DOT 3 or DOT 4 specification should be used. Thereservoir cap must be fully tightened to avoidcontamination from foreign matter or moisture. NOTE: Do not allow any other liquids to contami- nate the brake fluid. Seal damage will result. WARNING: Use caution when handling brake fluid. It can damage your vision if you get it in youreyes. It will also damage your vehicle's paintif spilled on it and not removed immediately. G140A01A-AAT
AIR CONDITIONING CARE Keeping the Condenser Clean
The air conditioning condenser (and engine radiator) should be checked periodically foraccumulation of dirt, dead insects, leaves, etc.These can interfere with maximum cooling effi-ciency. When removing such accumulations,brush or hose them away carefully to avoidbending the cooling fans.
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 theside of the reservoir. If the level is at or belowthe "MIN" mark, carefully add fluid to bring it upto "MAX". Do not overfill.
G120E02A-AAT
Adding Brake Fluid WARNING: Handle brake fluid carefully. It can damage your vision if it gets into your eyes. Use onlyDOT 3 or DOT 4 specification fluid from asealed container. Do not allow the fluid canor reservoir to remain open any longer thanrequired. This will avoid entry of dirt andmoisture which can damage the brake sys-tem and cause improper operation. To add brake fluid, first wipe away any dirt thenunscrew the fluid reservoir cap. Slowly pour therecommended fluid into the reservoir. Do notoverfill. Carefully replace the cap on the reser-voir and tighten. G130A01S-AAT
CHECKING THE CLUTCH FLUID (Manual Transaxle)To Check the Clutch Fluid
The clutch fluid level in the master cylinder should be checked when performing other un-der hood services. The system should bechecked for leakage at the same time. Check tomake certain that the clutch fluid level is alwaysbetween the "MAX" and "MIN" level markingson the fluid reservoir. Fill as required. Fluid lossindicates a leak in the clutch system whichshould be inspected and repaired immediately.Consult your Hyundai dealer.
HGK215HGK216

DO-IT-YOURSELF MAINTENANCE 6-17
G180A01A-GAT
CHECKING BRAKE PEDAL CLEARANCE
You need a helper to check the brake pedal clearance. With the engine running, have yourhelper press down on the brake pedal severaltimes and then hold it down with a force of about490N (50 kg, 110 lbs). The brake pedal clear-ance is the distance from the top surface of thebrake pedal to the asphalt sheeting under thefloor mat. If the brake pedal clearance is notwithin the limits specified in the illustration, haveit inspected by your Hyundai dealer and adjust-ed or repaired if necessary.
SSA6180A
45.1 mm (1.78 in.)
G170A01A-GAT
CHECKING BRAKE PEDAL FREE-PLAY
With the engine off, press down on the brake pedal several times to reduce the vacuum in thebrake booster. Then, using your hand, press down slowly on the brake pedal until you feel a change inresistance. This is the brake pedal freeplay.The freeplay should be within the limits speci-fied in the illustration. If it is not, have it inspect-ed by your Hyundai dealer and adjusted orrepaired if necessary.
SSA6170A
3 ~ 8 mm
(0.12 ~ 0.31 in.) G190A01A-GAT
CHECKING DRIVE BELTS
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 deteriorationand replaced if necessary. Belt routing should also be checked to be sure
there is no interference between the belts andother parts of the engine. After a belt is re-placed, the new belt should be adjusted againafter two or three weeks to eliminate slackresulting from initial stretching after use.
G190A01GK
V6
DOHC
Water Pump Pulley
Generator Pulley
Crankshaft Pulley 5.1~6 mm (0.2~0.24 in.)
Power steering
Auto tensioner
GeneratorEng.pulleyCOMP

VEHICLE SPECIFICATIONS 9-1
J030A01GK-GAT TIRE
1.6L
MF 60AH 90A
Dual hydraulic with brake booster Ventilated discSolid discCable
9. VEHICLE SPECIFICATIONS
J010A01GK-GAT MEASUREMENT
J060A01F-AAT FUEL SYSTEM
Type Wheel free playRack strokeOil pump type Rack and pinion0 ~ 30 mm (0 ~ 1.18 in.)132 mm (5.20 in.)Vane type
195/65 R15 205/55 R16, 215/45 R17
StandardOption
Overall length Overall widthOverall height (unladen)Wheel base
Front Rear
4395(173)
1760(69.3) 1330(52.4)2530(99.6)1490(58.7)1490(58.7)
Wheel tread mm (in.)
J020A01GK-GAT POWER STEERING
Fuel tank capacity Liter
55 US.gal
14.5 Imp.gal
12
J040A02GK-GAT ELECTRICAL
Item BatteryAlternator
J050A01GK-GAT BRAKE Type Front brake typeRear brake typeParking brake
J035A01GK-GAT SPARE TIRE
T125/70 R16 (Temporary)
Standard
2.0L
MF 68AH 90A2.7L
MF 68AH 95A
9

VEHICLE SPECIFICATIONS 9-3
Oil & Grease Standard
1.6L / 2.7L API SG or SAE 20W-40, 20W-50 (ABOVE -10°C)
ABOVE SAE 15W-40, 15W-50 (ABOVE -15°C) SAE 10W-30 (-25°C ~ 40°C) SAE 10W-40, 10W-50 (ABOVE -25°C)SAE 5W-20 *1, *2 (BELOW -10°C) SAE 5W-30 *1 (BELOW 10°C) SAE 5W-40 *1 (BELOW 20°C)
2.0L API SH or SAE 15W- 40 (ABOVE -10°C)
ABOVE, SAE 10W-30 (-25°C ~ 40°C)
ILSAC GF-1 SAE 10W-40 (ABOVE -25°C)
or ABOVE SAE 5W-20 (BELOW -10°C) *1, *2
SAE 5W-30 (BELOW 10°C) *1SAE 5W-40 (BELOW 20°C) *1
*1. Restricted to driving condition and vehicle destination*2. Not recommended for sustained high speed vehicle operationNormal driving condition Severe driving condition HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)DIAMOND ATF SP- III or SK ATF SP- III
PSF-3DOT 3 or DOT 4 equivalent Ethylene glycol base for aluminium radiator
J080A03GK-GAT
LUBRICATION CHART
Item
Engine Oil Engine Oil Consumption TransaxlePower Steering Brake Fluid CoolantQ'ty (liter) (us.qts., Imp.qts.)
Engine Oil: 1.6 L : 3.3 (3.5, 2.9)2.0 L : 3.85 (4.07, 3.39) 2.7 L : 4.5 (4.76, 4.0) Oil Pan: 1.6 L : 3.0 (3.17, 2.64) (MAX)
2.0 (2.11, 1.76) (MIN)
2.0 L : 3.55 (3.75, 3.12) (MAX) 2.6 (2.75, 3.3) (MIN)
2.7 L : 4.2 (4.44, 3.7) (MAX) 3.4 (3.59, 3) (MIN)
Oil Filter : 0.3 (0.32, 0.26) MAX. 1L / 1500 Km MAX. 1L / 1000 Km5 speed:2.15(2.27, 1.86) 6 speed:2.2(2.32, 1.94)
7.8 (8.2, 6.9) As requiredAs required 1.6L/2.0L : 7.0 (7.4, 6.2) 2.7L : 8.0 (8.5, 7.0)
Manual Auto

INDEX10-1
Catalytic Converter
.................................................................... 7-1 ~ 7-2
CD Auto changer (H250, H260) .............................................. 1-70, 1-77
Child Restraint system ........................................................... 1-14 ~ 1-19
Child Seat Restraint Suitability For Seat Position ............................1-18
Cigarette Lighter ................................................................................ 1-37
Clock ................................................................................................ 1-36
Clutch Checking fluid ............................................................................... 6-13
Pedal free play ............................................................................. 6-16
Combination Light Daytime running lights .................................................................. 1-34
Headlight flasher ........................................................................... 1-34
Headlight switch ........................................................................... 1-33
High-beam switch ......................................................................... 1-34
Lane change signal ...................................................................... 1-33
Turn signal operation .................................................................... 1-33
Compact Disk Player Operation (H260) ........................................... 1-75
Cooling Fans ..................................................................................... 6-19
Corrosion Protection Cleaning the interior ....................................................................... 4-3
Protecting your Hyundai from corrosion ................ ......................... 4-1
Washing and waxing ...................................................................... 4-2
Cruise Control ................................................................................... 1-47
D Defrosting/Defogging ......................................................................... 1-54
Door
Central door lock ............................................................................ 1-5
Door locks ...................................................................................... 1-3 Locking and unlocking front door with a key ................................. 1-4
Drink Holder ...................................................................................... 1-38
Drive Belts ........................................................................................ 6-17
ZK000A1-G 10. INDEX A
Air bag ....................................................................................
1-20 ~ 1-24
Air cleaner filter ................................................................................. 6-10
Air Conditioning Care .............................................................................................. 6-14
Operation ...................................................................................... 6-14
Switch ........................................................................................... 1-55
Air filter .............................................................................................. 1-62
Antenna ............................................................................................. 1-87
Ashtray .............................................................................................. 1-37
Audio Fault Code .............................................................................. 1-79
Automatic Transaxle ........................................................................... 2-6 B Battery ...................................................................................... 2-11, 6-18
Brake Anti-lock system ............................................................................. 2-9
Checking the brakes .................................................................... 6-13
Fluid .............................................................................................. 6-13
Pedal clearance ............................................................................ 6-16
Pedal free play ............................................................................. 6-16
Practices ......................................................................................... 2-8
Breaking-In your new Hyundai ........................................................... 1-1
C Care of Cassette tapes .......................................................... 1-85 ~ 1-86
Care of Disk ...................................................................................... 1-85
Cassette Tape Player Operation (H250) ..........................................1-68
10

INDEX10-3
R Rear Seats
Before Folding the Rear Seats ..................................................... 1-10
Fold down ..................................................................................... 1-10
Rear seat entry ............................................................................. 1-10
Rear Seat Pos itions ....................................................................... 1-9
Rear Window Defroster Switch ......................................................... 1-36
Rear Window Wiper and Switch .. ..................................................... 1-35
SSeat Belts 3-Point type .................................................................................. 1-13
Adjustable height .......................................................................... 1-13
Adjusting your seat belt ................................................................ 1-13
Care of seat belts ......................................................................... 1-12
Precautions ................................................................................... 1-11
Pre-tentioner Seat Belt ................................................................. 1-18
Spark Plugs ........................................................................................ 6-8
Spectacle Case ................................................................................. 1-40
Speedometer ..................................................................................... 1-30
Starting Procedures ............................................................................ 2-3Steering Wheel Free play ...................................................................................... 6-15
Tilt lever ........................................................................................ 1-47
Stereo Radio Operation (H250, H260) ....................................1-65, 1-72
Stereo Sound System ............................................................ 1-63 ~ 1-64Sun Visor .......................................................................................... 1-46
Sunroof .............................................................................................. 1-38
TTachometer ....................................................................................... 1-30
Tail Gate ........................................................................................... 1-45
TCS (Traction control system) .......................................................... 2-10
Theft Alarm System ............................................................................ 1-5
JJump Starting
...................................................................................... 3-1
K
Keys .................................................................................................. 1-2 If you lose your keys .................................................................... 3-10
Positions ......................................................................................... 2-2
L
Light Bulb Replacement .................................................................... 6-20
Lubrication Chart ................................................................................. 9-3
Luggage Net ...................................................................................... 1-47
M Maintenance Intervals Explanation of scheduled maintenance items ....................... 5-5 ~ 5-7
Maintenance under severe usage conditions ................................. 5-4
Scheduled maintenance ................................................................. 5-2
Service requirements ...................................................................... 5-1
Map Light .......................................................................................... 1-40
Mirros Day-night inside rearview ............................................................. 1-42
Outside rearview folding ............................................................... 1-42
Outsde rearview heating .............................................................. 1-41
Multi gauge ........................................................................................ 1-32
OOdometer .......................................................................................... 1-30
PParking Brake ................................................................................... 1-43
Power Steering Fluid Level ............................................................... 6-19

CAUTION:
When installing a container of liquid air freshener inside the vehicle, do not place it near the instrument cluster nor on the instrument panel surface. If there is any leakage from the air freshener onto these areas (Instrument cluster, instrument panel or air ventilator), it may damage these parts. If the liquid from the air freshener does leak onto these areas, wash themwith water immediately.!
1. Passenger's Drink Holder
2. Passenger's Side Air Bag (Not all models)
3. Multi Guage (Not all models)
4. Front Fog Light Switch (Not all models)
5. Rear Fog Light Switch
6. Digital Clock
7. Hazard Warning Switch
8. Front Seat warmer (Not all models)
9. Windscreen Wiper/Washer Switch
10. Steering Wheel Tilt Lever (Not all models)
11. Multi-Function Light
12. Panel Brightness Control Knob
(Rheostat Switch) (Not all models) 13. Electronic Stability Progrem (ESP) Switch
(Not all models)
14. Headlight Leveling Device
15. Centre Console
16. Glove Box
17. Parking Brake Lever
18. Shift Lever
19. Cigarette Lighter
20. Ashtray
21. Heating/Air Conditioning Control Panel
22. Horn and Driver's Airbag
23. Cruise Control Switch (Not all models)
24. Fuse Box Relay
25. Bonnet Release Lever

YOUR VEHICLE AT A GLANCE
B255A01GK-EAT INDICATOR SYMBOLS ON THE INSTRUMENT PANEL * More detailed explanations of these items will be found beginning on page 1-40.
Malfunction Indicator Light (Not all models)
SRS (Airbag) Service Reminder Indicator (SRI)(Not all models)
Hatchback Door Open Warning Light
Low Fuel Level Warning Light
Door Ajar Warning Light (Not all models)
ABS Service Reminder Indicator (Not all models)
Turn Signal Indicator Lights
High Beam Indicator Light Low Oil Pressure Warning Light Parking Brake/Brake Fluid Level Warning Light Charging System Warning Light
Cruise Indicator (Not all models)
Seat Belt Warning Light
CRUISE SET Indicator Light (Not all models)
Electronic Stability Program (ESP) Indicator Light (Not all models)
Immobiliser Warning Light