engine Hyundai Matrix 2004 Repair Manual

DO-IT-YOURSELF MAINTENANCE 6-11
NOTE: Spark plugs should be tightened firmly. Over- tightening can damage the threads in thealuminum cylinder head. Leaving them tooloose can cause the spark plugs to get veryhot and possibly result in damage to theengine.
7. Replace the cable by pushing the insulated connector directly down onto the electrode.Check to be sure it has snapped into placeand can't fall off.
SSA6061ASSA6062A
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 spark plug, turn the wrench handle in a counterclockwise direction.
6. To install the new spark plug, guide the socket down over the spark plug, beingcareful not to damage the ceramic insulator.
G060C01S-GAT
Changing the Spark Plugs
You will find it easier to change spark plugs if
the engine is cold. Always change one sparkplug at a time. This helps avoid getting the wiresmixed up.
1. Remove the center cover on the engine rocker cover.
2. Using a clean cloth, remove any dirt that has accumulated around the spark plug so it cannot fall into the cylinder when the sparkplug 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 carboncore conductor.
SSA6060B

DO-IT-YOURSELF MAINTENANCE
6-12
G090A01A-GAT FILLING THE WASHER RESERVOIR The washer fluid reservoir supplies fluid to the windshield washer system.A good quality washer fluid should be used to fillthe washer reservoir. The fluid level should bechecked more frequently during bad weather orwhenever the washer system is in more fre-quent use. The capacity of the washer reservoir is 3.0 liters (3.2 U.S. quarts).
HFC5010
G080A02A-AAT
WINDSHIELD WIPER BLADESHEF-119
The wiper blades should be carefully inspected from time to time and cleaned to remove accu-mulations of road film or other debris. To cleanthe wiper blades and arms, use a clean spongeor 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 Operating your vehicle without a proper air filter in place can result in excessiveengine wear.
o When removing the air cleaner filter, be careful that dust or dirt does not enterthe air intake. These may result in dam-age to the air cleaner filter.
G070A01E-AAT
CHANGING THE AIR CLEANER FILTER
Gasoline engine
Diesel engine
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 filterput in its place. Genuine Hyundai ReplacementParts are recommended.
HFC5003
G070A02FC NOTE:
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 engineoil, gasoline, etc.

DO-IT-YOURSELF MAINTENANCE 6-13
CAUTION:
o Radiator antifreeze (engine coolant) should not be used in the washer system because it will damage the car's finish.
o The washer lever should not be pulled and the washer should not be operated ifthe washer reservoir is empty. This candamage the washer fluid pump.
G100B02A-AAT
To Check the Maunal 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.
Filler plugG110A01E
Transaxle lubricant in the manual transaxle should
be checked at those intervals specified in the vehicle maintenance schedule in Section 5. G100A03A-GAT
CHECKING THE TRANSAXLE OIL (MANUAL)Drain plug Recommended Oil
Use only HYUNDAI GENUINE PARTS MTF
75W/90 (API GL-4) in the manual transaxle. Manual Transaxle Oil Capacity
The oil capacity of the manual transaxle is 2.15
liters (2.27 U.S. quarts).
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 greatcaution to avoid burning yourself on hotengine or exhaust parts.
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:
Basically automatic transaxle fluid is red color. As driving distance increases, the fluid color
turns darkish red gradually.
It is normal condition and you should not
judge replacing by changing color.
You must replace the automatic transaxle
fluid in accordance with intervals specifiedin the vehicle maintenances schedule insection 5.

DO-IT-YOURSELF MAINTENANCE
6-14 While the engine is idling, apply the brakes and move the gear selector lever from "P" to eachof its other positions -- "R", "N", "D", "2", "L" -- and then return to "N" or "P". With the enginestill 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, 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.Fluid level should be within this range
C090A03FC
ÎÎ
HFC5008
G110D03A-GAT
To Check the Transaxle Fluid Level
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.
C090A01FC
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 a
nonspecified fluid is not covered by your newvehicle limited warranty. G110C01FC-GAT
Transaxle Fluid Capacity The fluid capacity of the automatic transaxle is
6.1 liters (1.6 DOHC)/6.7 liters (1.8 DOHC).
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.

DO-IT-YOURSELF MAINTENANCE 6-15
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.
WARNING (Diesel only): Never work on injection system with engine
running or within 30 seconds after shutting off engine. High pressure pump, rail, injec-tors and high pressure pipes are subject tohigh pressure even after the engine stopped.The fuel jet produced by fuel leaks maycause serious injury, if it touch the body.People using pacemakers should not movethan 30cm closer to the ECU or wiring har-ness within the engine room while engine isrunning, since the high currents in the Com-mon Rail system produce considerable mag-netic fields.
The fluid level in the brake fluid reservoir shouldbe checked periodically. The level should bebetween 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.
G120D01A-AAT
To Check the Fluid Level
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.
HFC5005
G120D02FC
Gasoline engine
Diesel engine

DO-IT-YOURSELF MAINTENANCE
6-16 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.
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 always
G120D02FC
Diesel engine
G130A01S-AAT
CHECKING THE CLUTCH FLUID To Check the Clutch Fluid
HFC5005
Gasoline engine
between the "MAX" and "MIN" level markings on the fluid reservoir. Fill as required. Fluid lossindicates a leak in the clutch system whichshould be inspected and repaired immediately.Consult your Hyundai dealer.
G120E02A-AAT
Adding Brake Fluid 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 asealed container. Do not allow the fluid canor reservoir to remain open any longer thanrequired. This will prevent entry of dirt andmoisture 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 therecommended fluid into the reservoir. Do notoverfill. Carefully replace the cap on the reser-voir and tighten.

DO-IT-YOURSELF MAINTENANCE 6-17
G140B01A-AAT
Checking the Air Conditioning Operation
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.
2. If the air coming out of the in-dash vents is not cold, have the air conditioning systeminspected by your Hyundai dealer.
CAUTION: Running the air conditioning system for extended periods of time with a low refriger-ant level may damage the compressor. G140C01A-AAT
Lubrication To lubricate the compressor and the seals in the system, the air conditioning should be runfor at least 10 minutes each week. This isparticularly important during cool weather whenthe air conditioning system is not otherwise inuse.
G150A01A-GAT
CHECKING STEERING WHEEL FREEPLAY
To check the steering wheel freeplay, 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 sensitiveto changes in resistance that mark the limits ofthe freeplay. If the freeplay is greater thanspecified, have it inspected by your Hyundaidealer and adjusted or repaired if necessary.
G150A01FC
G140D01S-GAT
Checking the Compressor Drive Belt
When the air conditioning is being used regular- ly, the compressor drive belt tension should bechecked at least once a month. To check the drive belt tension, press down on the belt halfway between the engine crankshaftand compressor pulleys. Pressing with yourfinger, you should not be able to deflect this beltanymore than 8.0 mm. If you have the instru-ments to check it with a force of 98N (22 lb.),the deflection should be approx. 8.0 mm (0.315in.). If the belt is too loose, have it adjusted byyour Hyundai dealer.
G140D01A
A/C
CRANK PULLEY
TENSION PULLEY
30 mm (1.18 in.)
8mm(0.315 in.)

DO-IT-YOURSELF MAINTENANCE
6-18 G180A01A-GAT
CHECKING BRAKE PEDAL CLEARANCE
You need a helper to check the brake pedal
clearance. With the engine running, have your helper 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 the brake 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.)
G160A01A-GAT
CHECKING CLUTCH PEDAL FREE-PLAY
With the engine off, press lightly on the clutch
pedal until you feel a change in resistance. This is the clutch pedal freeplay. The freeplay shouldbe within the limits specified in the illustration. Ifit is not, have it inspected by your Hyundaidealer and adjusted or repaired if necessary.
G160A01E
6 ~ 13 mm (0.24 ~ 0.51 in.)

DO-IT-YOURSELF MAINTENANCE 6-19
G190A01A-GAT
CHECKING DRIVE BELTS (Gasoline Engine)
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.
SSA6190A
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley 5.1~6 mm (0.2~0.24 in.)
G200A01A-AAT
CHECKING AND REPLACING FUSES Replacing a Fusible Link
A fusible link will melt if the electrical circuits
from the battery are ever overloaded, thus pre- venting damage to the entire wiring harness.(This could be caused by a short in the systemdrawing 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 fuse box foreasy inspection.
CAUTION: When replacing a fusible link, never use
anything but a new fusible link with the same or lower amperage rating. Never use apiece of wire or a higher-rated fusible link.This could result in serious damage andcreate a fire hazard.
AS60310A
Bad Good
G190B01TB-GAT
CHECKING DRIVE BELTS (Diesel Engine)
At the scheduled maintenance inspection, belts should be examined for cracks, wear, fraying orother evidence of deterioration and replaced ifnecessary. Belt routing should also be checked to be sure there is no interference between the belts andother parts of the engine.G190B01O
Power steeringpump
A/C comp.
Alternator
Alternator

DO-IT-YOURSELF MAINTENANCE 6-21
G210A01A-AAT
CHECKING THE BATTERY
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 solu-
tion of sulfuric acid, which is poisonous andhighly corrosive. Be careful not to spill it onyourself or the car. If you do spill battery fluid onyourself, 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 assistanceas soon as possible. While you are beingdriven to get medical assistance, continueto rinse your eyes by using a sponge or softcloth saturated with water.
D010B01FC
G220A01A-AAT
CHECKING ELECTRIC COOLING FANS 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 coolant 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. G220B01A-AAT
Checking Engine Cooling Fan The engine coolant fan should come on auto- matically if the engine coolant temperature ishigh. G220C01A-AAT
Checking Condenser Cooling Fan The condenser coolant fan should come on automatically whenever the air conditioning isin operation.
G210B01A-AAT
Checking the Battery Keep the battery clean. Any evidence of corro-
sion around the battery posts or terminals shouldbe removed using a solution of household bak-ing soda and warm water. After the batteryterminals are dry, cover them with a light coat-ing of grease.
o If you swallow battery fluid, drink a large
quantity of water or milk followed by milk ofmagnesia, eat a raw egg or drink vegetableoil. Get medical assistance as soon aspossible.
While batteries are being charged (either by abattery charger or by the vehicle’s alternator),they produce explosive gases. Always observethese warnings to prevent injuries from occur-ring:
o Charge batteries only in a well ventilated area.
o Do not permit flames, sparks or smoking in the area.
o Keep children away from the area.