Hyundai H-1 (Grand Starex) 2005 Owner's Manual

8DO-IT YOURSELF MAINTENANCE
22CHECKING DRIVE BELTS
G180A01A-GAT CHECKING BRAKE PEDAL CLEARANCE
G180A01L
45.1 mm (1.78 in.)
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 andthen hold it down with a force of about 490N (50 kg, 110 lbs). The brake pedal clearance is the distance fromthe top surface of the brake pedal to the asphalt sheeting under the floor mat. If the brake pedal clearance isnot within the limits specified in the illustration, have it inspected by your Hyundai dealer and adjusted or re-paired if necessary.
G170A01A-GAT Brake Pedal With the engine off, press down on the brake pedal several times to re-duce the vacuum in the brake booster.Then, using your hand, press downslowly on the brake pedal until you feel a change in resistance. This is the brake pedal freeplay. The freeplayshould be within the limits specified in the illustration. If it is not, have it inspected by your Hyundai dealer andadjusted or repaired if necessary.
3 ~ 8 mm (0.12 ~ 0.31 in.)
G160A01E G190A01P-GAT
G190D01P-1
Diesel (2.5 CRDi)
Diesel (2.5 TCI)
HSM396-1
Gasoline
Auto tensioner pulley COMP.pulley
Engine pulley
Power steering pulley
Generator pulley
Generator pulley Crankshaftpulley
COMP.pulley
Tensionpulley
Water pump pulley
Power steering pulley
Generator pulley
Idler pulleyWater pump pulley
Idler pulley COMP.pulley
Powersteeringpulley Autotensioner
Crankshaft pulley Idler pulley

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DO-IT YOURSELF MAINTENANCE
23
I230A01P-GAT PARKING BRAKE LEVER STROKE Pull the parking brake lever all the way up to check the number of "clicks" that the ratchet makes. One click represents a lever movement of onenotch. The lever should move the specified number of notches for nor- mal brake application. Parking brake lever stroke; If the parking brake lever stroke is not within the standard range(5 to 7 notches), have the brake lever ad-justed at an authorized HYUNDAI dealer. D030A01P
TIRE
I150A02P-GAT Tire condition Check the tires for cuts, cracks and other damage. Replace the tires if there are deep cuts or cracks. Also check each tire for pieces of metal orpebbles.The use of worn tires can be verydangerous because of the greater chance of skidding or hydroplaning. The tread depth of the tires mustexceed 1.6 mm (0.06 in.) in order for the tires to meet the minimum re- quirement for use. If there are belt-line wear indicators on the tires, they will appear in six places on the surface of the tirethereby indicating that the tire no 1.6 mm (0.06 in.)
I090A01A
Wear indicator
Drive belts should be checked peri-
odically for proper tension and ad-justed if necessary. At the same time, belts should be examined for cracks, wear, fraying or other evidence ofdeterioration and replaced if neces- sary.
Belt routing should also be checked
to be sure there is no interferencebetween 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 stretchingafter use.
NOTE: The drive belt tension for diesel
engine (2.5 CRDi only) is adjusted automatically.

8DO-IT YOURSELF MAINTENANCE
24
Vehicle
MINIBUS
longer meets the minimum require- ment for use. When these wear indi-cators appear, the tires must be re- placed with new one. Confirm that the wheel nuts are tightened sufficiently.Refer to the section of this manual entitled "In case of emergency" for information concerning care of thetires.
!WARNING:
o Driving on worn-out tires is dan- gerous! Worn-out tires can cause loss of braking effective- ness, steering control and trac- tion. When replacing tires, nevermix radial and bias-ply tires on the same car. If you replace ra- dial tires with bias-ply tires, theymust be installed in sets of four.
o Using tires and wheels of other
than the recommended sizesmay cause unusual handling characteristics that may cause death, serious injury or prop-erty damage. I160A03P-GAT Tire inflation pressure
kg/cm² (psi)
Tire size
205/70R 15 215/80R 15205/70R 15C-6PR205/70R 15C-8PR Rear
2.8(40)2.2(32)2.8(40)4.5(65)
Front
2.8(40)2.2(32)2.8(40)2.8(40)
Vehicle VAN
TRUCK Tire size
205/70R 15C-8PR
195R 14C-6PR 195R 13C-8PR Rear
4.5(65)
-
3.5(50)
Front
2.8(40)2.8(40) -
kg/cm² (psi)
Check the tire inflation pressure of all the tires while they are cold; if insuf- ficient or excessive, adjust to the specified value.After the tire inflation pressure hasbeen adjusted, check the tires fordamage and air leaks.Be sure to put rubber caps on thevalves. I160A02P

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DO-IT YOURSELF MAINTENANCE
25
Tires tend to wear unevenly over a long period of service. To make surethat the tires wear evenly as possible and for longer tire life, rotate the wheels in the sequence illustrated. Take the vehicle to an authorized HYUNDAI dealer to have the chance of the wheels properly adjusted.
CAUTION:
If the front wheels are of a different type from the rear and spare wheels, do not attempt to mountthe wheel for front onto rear. In this instance, use the type 2 wheel rotation method.
!
I240A01P-GAT
Rotation
Bias tires
Radial tires HSRFL151
HSRFL152

Measurement................................................................ 9-2
Engine ........................................................................... 9-3
Lubrication Chart .......................................................... 9-4
9
VEHICLE SPECIFICATIONS
9

9 VEHICLE SPECIFICATIONS
2
2WD
1,885(74)
SHORT
3
VAN
4,695(184)
1,820(71)1,900(74)
2,810(110)
1,570(61)1,545(60)
Front Rear
J010A03P-GAT MEASUREMENT J010A02P-GAT MEASUREMENT
J020A02P-GATFUEL TANK SYSTEMmm (in.)
MINIBUS, VAN
Overall length Overall widthOverall height Wheel base Wheel tread
ITEMS FUEL TANK CAPACITYMINIBUS, VAN 65L TRUCK
70LLONG(1ton)
STANDARD
5085 (200)1820 (71)
3080 (121)
1570 (62) 1408 (55) EXTRA LONG (1.25 ton)
STANDARD
5415 (213)1820 (71)
3280 (129)
1570 (62)1408 (55)TRUCK
Overall length Overall width Wheel base Wheel tread
Front Rear
SUPER
mm(in.)
12

9

1,970(77)
6
VAN
3
VAN
5,035(198)

1,980(77)
3,080(121)

9
4,695(184)
1,885(74)
1,570(61)1,545(60)
4WD
4,825(189)

1,995(78)
1,565(61)1,560(61)
6
VAN
LONG
7

9
VEHICLE SPECIFICATIONS
3ENGINE
J040A06P-GAT J050A02P-GPT SISTEMA ELÉCTRICO 2.5 4D56
2,476 cc
20.5
Elec.:ATDC 9°±1°
Mech.:ATDC 7°±1° (A tropical region)
Mech.:ATDC 9°±1°
(Except a tropical region) 750 ± 100
ITEMS Engine typeTotal displacement Compression ratio Firing order Injection (or Ignition) timingIdle speed (RPM) 2.6 N/A
2,607 cc
22
1 - 3 - 4 - 2
ATDC 5°
850 ± 100DIESEL
GASOLINE (Minibus/Van) 12V-68AH MF
13.5V-110A12V-1.2 kw
* PARA UTILIZAÇÃO APENAS EM ZONAS FRIAS
GASOLINE 2.4 DOHC
2,351 cc 10

BTDC 8°± 5° 750 ± 100
2.5 CRDi
2,497 cc
17.6
-
800 ± 100
ITEMS Bateria Alternador Motor arranque DIESEL
12V-90AH MF, 100AH MF*
12V- 2.2kw
2.5 CRDi 4D56 TCI(Con A/CON) 4D56 TCI(Sen A/CON) 12V-110A 12V-110A
12V-75A

9 VEHICLE SPECIFICATIONS
4
OIL & GREASE STANDARDSAE 30 (ABOVE 0°C) SAE 20W-40 (ABOVE -10°C)SAE 15W-40 (ABOVE -15°C)SAE 10W-30 (-20°C ~ 40°C)SAE 5W-30 (-25°C ~ 40°C)SAE 0W-30 (BELOW 10°C) *1SAE 30 (0°C ~ 40°C)SAE 20W-40 (ABOVE -10°C)SAE 15W-40 (ABOVE -15°C)SAE 10W-30 (-20°C~ 40°C)SAE 5W-30 (-25°C~ 40°C)SAE 0W-30 (BELOW 10°C) *1SAE 5W-20, 5W-30SAE 10W-30 (ABOVE -18°C)SAE 15W-40 (ABOVE -13°C)SAE 20W-50 (ABOVE -7°C)
NORMAL DRIVING CONDITIONSEVERE DRIVING CONDITIONLUBRCATION CHART
J060A08P-GAT
*1. Restricted by driving condition and area.
*2. SAE 5W-20 not recommended for sustained high speed vehicle operation.
DESCRIZIONE
ENGINE OIL (DIESEL) ENGINE OIL (GASOLINE) ENGINE OIL CONSUMPTIONQUANTITY (LITER)
Engine Oil : 6.1 at Oil Pan : 4.9
Engine Oil : 7.4 at Oil Pan : 6.6 (MAX) 4.9 (MIN)
Engine Oil : 4.3 at Oil Pan : 4.0 (MAX) 3.0 (MIN)
at Oil Filter : 0.3
Max. 1L/ 1,500 km Max. 1L/ 1,000 km
API CF-4 or ABOVE API CF-4 or ABOVE ACEA B2 or B3 API CF-4 or ABOVE ACEA B4 or ABOVE API SJ, SL or ABOVE, ILSAC GF-3 or ABOVE
2.6 N/A 2.5 4D56 TCI 2.5 CRDi TCI

9
VEHICLE SPECIFICATIONS
5
J060A08P-GAT QUANTITY (LITER)
Minibus, Van : 1.3 0.8
Minibus : 13, Van : 10, Truck : 7.2As requiredAs required
Minibus, Van : 2.6, Truck : 1.7 As required
OIL & GREASE STANDARD
HYUNDAI GENUINE PARTS MTF 75W/85 (API GL-4) MOBIL DEXRON-II or DIAMOND ATF SP-I DIAMOND ATF SP II PSF-3HIGH QUALITY ETHYLENE GLYCOL BASE FORALUMINUM RADIATORSAE J 1703 EQUIVALENTSAE J310a, MULTI-PURPOSE GREASE NLGI-2 OREQUIVALENT.API GL-4 (MS517-15) : SAE 90, 140API GL-5 (MS517-15) : SAE 80
ITEMS
MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL TRANSFER CASE OIL POWER STEERING OIL COOLANTCLUTCH & BRAKE FLUIDFRONT, REAR WHEEL BEARINGREAR AXLE STEERING GEAR BOX
GASOLINE DIESEL
GASOLINE
DIESEL 2.0
2.6 N/A : 2.4 2.5 4D56 TCI : 2.42.5 CRDi TCI : 3.2 7.53
2.6 N/A(long van): 8.5 2.6 N/A: 7 2.5 4D56 TCI(2WD) : 7.92.5 4D56 TCI(4WD) : 9.832.5 CRDi TCI(2WD) : 8.32.5 CRDi TCI(4WD) : 11.7

INDEX
10
10