Hyundai Getz 2004 Owner's Manual

6- 20 DO-IT-YOURSELF MAINTENANCE
B145A01TB-EAT
CHANGING THE POLLEN FIL-
TER (In Front of evaporator unit)
(Not all models)
The pollen filter is located in front of the
evaporator unit behind the glove box.
It operates to decrease pollutants from
entering the car and to filter the air.
1. Remove the adjusting pins on both
sides of the glove box to open half
the glove box.
HTB290-D
SG140D1-E
Off Season Maintenance
The air conditioning must be run for ten
minutes or so weekly during periods
when the system would not normally be
used to ensure that the compressor and
seals are lubricated. If this precaution
is not observed the compressor seals
may become stuck to the compressor
shaft and damaged when the system is
next used resulting in a loss of refriger-
ant and damage to the compressor.
SG140C1-E
Checking the Refrigerant
1. Start the engine and run at idle for
several minutes with the refrigera-
tion system running at the coldest
setting.
2. Open the bonnet and inspect the sight glass on the top of the receiver
dryer.
3. If the refrigerant charge is insuffi- cient, a flow of bubbles will be ob-
served through the sight glass.
4. If the refrigerant charge is satisfac- tory, no bubbles will be observed
through the sight glass. CAUTION:
Running the air conditioning system
with a low refrigerant level may dam-
age the compressor.
!
The air conditioning compressor drive
belt should be checked to ensure free-
dom from damage or excessive wear
and correct tension. The belt tension is
correct when the belt deflects by about
0.3 inches (8 mm) (1.1L: 5 ~ 5.5 mm)
when a force of 98 N is applied to the
belt halfway between the compressor
and crankshaft pulleys. Adjustment of
the belt should be entrusted to a Hyundai
dealer.
tbuk-6.p65
3/23/04, 4:26 PM
20

DO-IT-YOURSELF MAINTENANCE 6- 21
SG150A1-E
STEERING WHEEL FREEPLAY
Steering wheel freeplay should be
checked to ensure that the specified
value is not exceeded.
HTB293-D
4. Replace the two filters.
CAUTION:
Be sure to install the pollen filter in
the direction of the arrow sign. Un-
less, it may cause noise or deteriora-
tion.
5. Installation is the reverse order of disassembly.
!
3. Remove the filter cover to push the upside of the filter cover.
HTB291-D
2. Remove the cable and the wiring from the filter cover.
HTB292-D HTB161
1.18 in.
(30 mm)
tbuk-6.p65
3/23/04, 4:26 PM
21

6- 22 DO-IT-YOURSELF MAINTENANCE
G180A01A-GAT
CHECKING BRAKE PEDAL
CLEARANCE
G180A01L
1.78 in. (45.1 mm)
You need a helper to check the brake
pedal clearance. With the engine run-
ning, have your helper press down on
the brake pedal several times and then
hold it down with a force of about 490
N (50 Kg, 110 lbs). The brake pedal
clearance is the distance from the top
surface of the brake pedal to the as-
phalt sheeting under the floor mat.
If the brake pedal clearance is not
within the limits specified in the illustra-
tion, have it inspected by your Hyundai
dealer and adjusted or repaired if nec-
essary.SG170A1-E
BRAKE PEDAL FREEPLAY
HXGS508
0.12 ~ 0.31 in.
(3 ~ 8 mm)
The brake pedal freeplay should be
checked with the engine turned off. The
pedal to floor clearance should be
checked with the engine running and a
load of 490 N applied to the pedal. If
either value is incorrect, the necessary
adjustment should be performed by a
Hyundai dealer. Pedal to floor clear-
ance: 1.97 in. (50 mm)SG160A1-E
CLUTCH PEDAL FREEPLAY
G160A01E
0.24 ~ 0.51 in.
(6 ~ 13 mm)
The clutch pedal freeplay should be
checked against the specified value. If
the freeplay is not correct, the clutch
should be adjusted by a Hyundai dealer.
tbuk-6.p65 3/23/04, 4:27 PM
22

DO-IT-YOURSELF MAINTENANCE 6- 23
The various engine drive belts must be
checked for condition, tension and free-
dom from damage and excessive wear.
The tension of a new belt must be
checked after thirty minutes running
following fitment of the new belt to allow
for the initial belt stretch. G190B01TB-GAT
CHECKING DRIVE BELTS
(Diesel)
A/C comp.
Auto tensioner
Pulley
G190B01TB
AlternatorPower
steering
pump
At the scheduled maintenance inspec-
tion, belts should be examined for
cracks, wear, fraying or other evidence
of deterioration and replaced if neces-
sary.
Belt routing should also be checked to
be sure there is no interference be-
tween the belts and other parts of the
engine.
Crankshaft Pulley
SG190A1-E
DRIVE BELTS (Gasoline)
1.1L
1.3L/1.6L Alternator
0.37 ~ 0.43 in.
(9.5 ~11.0 mm)
Water Pump Pulley
Alternator
Pulley
0.2~0.24 in.
(5.1~6 mm)
HTB186
Crankshaft pulley
HTB220
Water Pump Pulley
tbuk-6.p65 3/23/04, 4:27 PM
23

6- 24 DO-IT-YOURSELF MAINTENANCE
!
!
SG200A1-E
FUSIBLE LINKS
The fusible link prevents damage to the
wiring harness in the event of an elec-
trical system malfunction. Failure of a
fusiblelink is indicative of a serious
overload condition having occurred and
therefore the electrical system should
be checked by a Hyundai dealer before
a replacement link is fitted.
WARNING:
Under no circumstances should a
fusible link be replaced with any-
thing other than a new link of the
same rating. The use of higher rated
links or other means of connecting
the circuit will create a potential fire
hazard.G200B01E-EAT
INDIVIDUAL CIRCUIT FUSES
The fuse box containing the individual
circuit fuses will be found in the back-
side of multi box located in the right side
of driver. The multi box is removed by
pulling lightly and then releasing the lid.
A fuse rating grid will be found on the
reverse side of the cover. In the event
of fuse failure, the fuse should be re-
placed with one of equivalent rating. A
fuse removal tool is provided within the
fuse box to facilitate replacement.
In the event of a replacement fuse
failing shortly after installation a mal-
function within the circuit protected by
that fuse is indicated. The circuit should
be checked by a Hyundai dealer at the
first available opportunity. HTB180-D
HTB223
WARNING:
The use of replacement fuses having
a higher rating than specified or other
means of connecting the circuit will
create a potential fire hazard.
tbuk-6.p65 3/23/04, 4:27 PM
24

DO-IT-YOURSELF MAINTENANCE 6- 25
!
!
o If battery electrolyte is spilled onto
skin or into eyes, the effected area
must be flushed with copious
amounts of water and medical assis-
tance sought.
o If battery electrolyte is ingested, copious amounts of water or milk
followed by an ant-acid (raw egg or
milk of magnesia) must be drunk.
Vomiting should not be induced and
medical assistance must be sought.
o Batteries must only be charged in well venti-lated areas from which
naked lights or sources of sparks are
excluded.
o Ensure that children, pets or other unauthorized persons are kept away
from batteries.
o Do not allow anything to bridge the positive (+) and negative (-) termi-
nals of the battery.
o Never invert the battery.
The battery fitted during production is of
the "Maintenance Free" type.
SG210A1-E
BATTERY MAINTENANCE
WARNING:
Motor vehicle batteries contain
sulphuric acid which is corrosive
and poisonous. Hydrogen gas is
emitted from the battery which is
explosive when combined with oxy-
gen. The following precautions must
be strictly observed to avoid per-
sonal injury or damage to the ve-
hicle.
HTB165 SG220A1-E
ELECTRIC COOLING FANS
WARNING:
The cooling fan is controlled by en-
gine coolant temperature and may
sometimes operate even when the
engine is not running. Use extreme
caution when working near the
blades of the cooling fan so that you
are not injured by a rotating fan
blade. As the engine coolant tem-
perature decreases, the fan will auto-
matically shut off. This is a normal
condition.
The engine cooling fan should operate
before the temperature gauge reaches
the upper portion of the scale and the
condenser fan should operate when-
ever the air conditioning is in use.
tbuk-6.p65 3/23/04, 4:27 PM
25

6- 26 DO-IT-YOURSELF MAINTENANCE
HTB287
SG230B1-E
POWER STEERING HOSES
Power steering hoses should be
checked for damage, deterioration and
leakage at each service.
steering fluid level is between the "MAX"
and "MIN" level markings on the fluid
reservoir.
NOTE:
Grinding noise from power steering
pump may be heard immediately
after the engine is started in extremely
cold condition (below -4

DO-IT-YOURSELF MAINTENANCE 6- 27
!
5. Open the bonnet.
6. Draw the vertical line (through the
center of each headlight beam pat-
tern) and the horizontal line (through
the center of each headlight beam
pattern) on the aiming screen.
And then, draw the horizontal paral-
lel line at 1.18 in. (30 mm ) under the
horizontal line.
7. Adjust each cut-off line of the low beam to the parallel line with a phillips
screwdriver - VERTICAL AIMING.
8. Adjust each cut-off line of the low
beam to each vertical line with a
phillips screwdriver - HORIZONTAL
AIMING. HTB269
Horizontal Aiming
Vertical
Aiming
G290A01FC-EAT
HEADLIGHT AIMING ADJUST-
MENT
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 and rear
bumper down several times. Place
the vehicle at a distance of 118 in.
(3,000 mm) 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 lights lens and turn
on the headlight (low beam). WARNING:
Be sure to carefully wipe away any
water drained out in this manner,
because the fuel mixed in the water
might be ignited and result in a fire.
1. Remove the engine cover.
2. Disconnect the air intake hose from air cleaner cover.
3. Loosen the drain plug at the bottom
of the fuel filter.
4. Tighten the drain plug when water no longer comes out.
5. Check to be sure that the warning lamp illuminates when the ignition
key is turned to "ON", and that it
goes off when the engine is started.
If in doubt, consult your nearest au-
thorized HYUNDAI dealer.
G300B01FC
tbuk-6.p65 3/23/04, 4:27 PM
27

6- 28 DO-IT-YOURSELF MAINTENANCE
SPECIFICATIONS:
"H"
Horizontal center line of headlights
from ground.
: 26.8 in.(656 mm)
"W"
Distance between each headlight
center.
: 43.3 in. (1,100 mm)
"L"
Distance between the headlights
and the wall that the lights are tested
against.
: 118 in. (3,000 mm). G270A01TB-EAT
REPLACING LIGHT BULBS
Headlight Bulb
In the event of bulb failure being expe-
rienced, ensure that the relative lighting
circuit is turned off prior to attempting to
replace the bulb. The illustrations on
the following page will assist in locating
and removing the various bulbs. En-
sure that the replacement bulb has the
same cap configuration and wattage as
the original.
!
CAUTION:
Keep the lamps out of contact with
petroleum product, such as oil, gaso-
line, etc.
If the vehicle has had front body repair
and the headlight assembly has been
replaced, the headlight aiming should
be checked using the aiming screen as
shown in the illustration. Turn on the
headlight switch. (Low Beam Position)
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.
G290B01TB-EAT
Adjustment After Headlight As-
sembly ReplacementG290B01L
L
W
H
H Cut-off line
Ground
line
"P"
Horizontal line0.59in. (15mm)
1.18 in. (30mm) Vertical line
tbuk-6.p65
3/23/04, 4:27 PM
28

DO-IT-YOURSELF MAINTENANCE 6- 29
!
HTB183
HTB268HTB184
Replacement instructions:
1. Allow the bulb to cool. Wear eye
protection.
2. Always grasp the bulb by its plastic base, avoid touching the glass.
3. Disconnect the power cord from the bulb base in the back of the head-
light.
4. Remove the dust cover. 5. Push the bulb spring for removing
the headlight bulb. 6. Remove the protective cap from the
replacement bulb and install the new
bulb by matching the plastic base
with the headlight hole. Install the
dust cover after retightening the bulb
spring and reconnect the power cord.
7. Use the protective cap and carton to dispose of the old bulb.
8. Check for proper headlight aim.
WARNING
The halogen bulb contains gas un-
der pressure and if impacted could
shatter, resulting in flying fragments.
Always wear eye protection when
servicing the bulb. Protect the bulb
against abrasions or scratches and
against liquids when lighted. Turn
on the bulb only when installed in a
headlight. Replace the headlight if
damaged or cracked. Keep the bulb
out of the reach of children and dis-
pose of the used bulb with care.
tbuk-6.p65 3/23/04, 4:27 PM
29