check engine Hyundai Terracan 2003 Owner's Guide

DO-IT-YOURSELF MAINTENANCE
6-12
G110D02HP-GAT
To Check the Transmission Fluid Level
G110D03HP
Park the car on level ground with the parking brake engaged. When the transmission fluid level is checked, the transmission fluid should be at normal operating temperature and the engine idling.
G110C03HP-GAT
Transmission Fluid Capacity The fluid capacity of the automatic transmission
is; Gasoline - 10.5 liters (11.09 U.S. quarts) Diesel (2.9 CRDi) - 11.8 liters (12.47 U.S. quarts)
Diesel (2.5 TCI) - 8.2 liters (8.66 U.S. quarts)
WARNING:The transmission fluid level should be
checked when the engine is at normal oper- ating temperature. This means that the en- gine, radiator, exhaust system etc., are very hot. Exercise great care not to burn yourself during this procedure.
G110A01HP-GAT
CHECKING THE TRANSMISSION FLUID (AUTOMATIC) Transmission fluid in the automatic transmis- sion should be checked at those intervals speci- fied in the vehicle maintenance schedule in Section 5. G110B01HP-GAT Recommended FluidYour Hyundai automatic transmission is spe- cially designed to operate with DEXRON- II or
DEXRON -III. Damage caused by a nonspecified
fluid is not covered by your new vehicle limited warranty.
3. Replace the plug and washer, screw it in
with your fingers and then tighten securely with the wrench.
G110D01HP-D
Gasoline
G100B01HP-GAT To Check the Manual Transmission Fluid LevelG100B01HP
WARNING: It is always better to check the transmissionoil 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. 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 to feel inside the hole. The oil level should be at its bottom edge. If it isnot, check for leaks before adding oil. To refill the transmission or bring the oil level up,add oil slowly until it reaches the proper level. Do not overfill.

DO-IT-YOURSELF MAINTENANCE 6-13
G110D03Y
Fluid level should be within "HOT" range
G120A01A-AAT CHECKING THE BRAKESCAUTION: 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.
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 the blades of the cooling fan, so that you are not injured by a rotating fan blade. As the en- gine coolant temperature decreases, the fan will automatically shut off. This is a normal condition. G120B02A-AAT Checking the Brake Fluid Level WARNING: Use caution when handling brake fluid. Itcan damage your vision if it gets into your eyes. It will also damage your vehicle’s paint if spilled on it and not removed immediately. G120C02A-AAT Recommended Brake FluidUse 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 LevelThe 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.
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", "2", "L" — 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.
2. Remove the transmission 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.
3. If the transmission fluid level is low, use a funnel to add transmission fluid through thedipstick tube until the level reaches the "HOT" range. Do not overfill.
Diesel (2.9 CRDi)
Diesel (2.5 TCI)
G110D02HP

DO-IT-YOURSELF MAINTENANCE
6-14 G140A01A-AAT
AIR CONDITIONING CARE Keeping the Condenser Clean
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 effi- ciency. When removing such accumulations, brush or hose them away carefully to avoid bending the cooling fans. G130B02A-AAT
To Replace the Fluid 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.
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 immediately.
G130A01A-AAT
CHECKING THE CLUTCH FLUID To Check the Clutch Fluid
G130A01HP
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 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 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.
G120E01HP

DO-IT-YOURSELF MAINTENANCE 6-15
anymore 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 (0.315 inches). If the belt is too loose, have it adjusted by your Hyundai dealer. NOTE: The compressor drive belt tension for diesel engine (2.9 CRDi only) is adjusted automati- cally.
B145A01HP-GAT CHANGING THE AIR FILTER (For Evaporator and Blower Unit) (If installed) The air filter is located in front of the evaporator unit behind the glove box. It helps to decrease pollutants from entering the car and to filter the air.
B760A01HP
Stopper
Diesel (2.5 TCI)
G140D01HP-GAT Checking the Compressor Drive Belt When the air conditioning is being used regular- ly, the compressor drive belt tension should be checked at least once a month. To check the drive belt tension, press down onthe belt halfway between the engine crankshaft and compressor pulleys. Pressing with your finger, you should not be able to deflect this belt
G140D01HP-D
G140D02HP
Gasoline
Generator pulley
Idler pulley Water pump pulley
COMP.pulley Auto tensionerCOMP. pulley
Crankshaft pulley Diesel (2.9 CRDi)
Crankshaft pulleyCOMP. pulleyCrankshaft pulley
Tension pulley
Tension pulley
G140B01A-AAT Checking the Air Conditioning Opera- tion
1. Start the engine and let it run at 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 forextended periods of time with a low refriger- ant level may damage the compressor. G140C01A-AAT LubricationTo 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.

DO-IT-YOURSELF MAINTENANCE 6-17
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 should be within the limits specified in the illustration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.
SSA6160A
6 ~ 13 mm (0.24 ~ 0.51 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 in resistance. 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 or repaired if necessary.
SSA6170A
3 ~ 8 mm (0.12 ~ 0.31 in.)
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 sensitive to changes in resistance that mark the limits of the freeplay. If the freeplay is greater than specified, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.
G150A01HP
Maximum
30 mm (1.18 in)

DO-IT-YOURSELF MAINTENANCE
6-18
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 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 for easy inspection.
G200A01HP
Bad
Good
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 re- placed, the new belt should be adjusted again after two or three weeks to eliminate slack resulting from initial stretching after use.
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 deterioration and replaced if necessary. Diesel (2.5 TCI)
G190D01HP
G190D02HP
Gasoline
Generator pulley
Idler pulley Water pump pulley
COMP.pulley Autotensioner
Crankshaft pulley
Diesel (2.9 CRDi)
Crankshaft pulleyCOMP. pulley
Generator pulley Power steering pulley
Idler pulley Tension pulley
COMP. pulley
Power steering pulley
Water pump pulley Tension pulley Power steering pulley
Crankshaft pulleyTension pulleyGenerator pulley
Tension pulley
Tension pulley
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 several times and then hold it down with a force of about 490N (50 kg, 110 lbs). 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 inspected by your Hyundai dealer and adjust- ed or repaired if necessary.
SSA6180A
71 mm (2.80 in.)

DO-IT-YOURSELF MAINTENANCE
6-20
G220B01A-AAT Checking Engine Cooling FanThe engine coolant fan should come on auto- matically if the engine coolant temperature is high. G220C01A-AAT Checking Condenser Cooling FanThe condenser coolant fan should come on automatically whenever the air conditioning is in operation. G230A03A-AAT POWER STEERING FLUID LEVEL
G230A01HP
Gasoline or Diesel (2.5 TCI)
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. G210B01A-AAT Checking the BatteryKeep the battery clean. Any evidence of corro- sion around the battery posts or terminals should be removed using a solution of household bak- ing soda and warm water. After the battery terminals are dry, cover them with a light coat- ing of grease. 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 the blades of the coolant fan, so that you are not injured by a rotating fan blade. As the en- gine coolant temperature decreases the fan will automatically shut off. This is a normal condition.
G210A01A-AAT CHECKING THE BATTERYWARNING: 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 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:
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 being driven to get medical assistance, continue to rinse your eyes by using a sponge or soft cloth saturated with water.
o If you swallow battery fluid, drink a large quantity of water or milk followed by milk ofmagnesia, eat a raw egg or drink vegetable oil. Get medical assistance as soon as possible.
While batteries are being charged (either by a battery charger or by the vehicle’s alternator), they produce explosive gases. Always observe these warnings to prevent injuries from occur- ring:

DO-IT-YOURSELF MAINTENANCE 6-21
G350A01HP-GAT BLEEDING THE FUEL SYSTEM
(FOR DIESEL ENGINE (2.5 TCI))
E090A01HP
The fuel system should be bled to remove air as described in the illustration if the fuel supply is exhausted during travel, when the fuel filter is replaced, or if the vehicle is not used for a long time.
G240A01A-AAT POWER STEERING HOSESIt is suggested that you check the power steer- ing hose connections for fluid leakage at regular intervals. The power steering hoses should be replaced if there is severe surface cracking, pulling, scuffing or worn spots. Deterioration of the hose could cause premature failure.
NOTE: Do not start the engine when the powersteering oil reservoir is empty.
2. Pump the hand pump until there are no more
bubbles in the fuel coming out of the air plug. When doing this, place a cloth around the air plug to prevent the escaping fuel from spew- ing about.
3. Tighten the air bleed bolt when there are no more bubbles in the fuel.
4. Continue pumping until the hand pump be- comes stiff.
5. Finally, check to be sure that there is no leakage of fuel.If in doubt, consult your nearest authorizedHYUNDAI dealer.
WARNING:
(1) Do not smoke or have any other open flame near the vehicle while bleeding the fuel system.
E090A02HP
1. Loosen the air bleed bolt at the top of the fuel
filter with a flat-bladed screwdriver or equiva- lent.
The power steering fluid level should be checked daily. To check the power steering fluid level, be surethe ignition is "OFF", then check to make cer- tain that the power steering fluid level is be- tween the "MAX" and "MIN" level markings on the fluid reservoir. NOTE: Grinding noise from the power steering pump may be heard immediately after the engine is started in extremely cold condi- tions (below - 20°C). If the noise stops dur- ing warm up, there is no abnormal function in the system. If is due to a power steering fluid characteristic in extremely cold condi- tions. Recommended Fluid Use PSF-3 type fluid.
G230A02HP
Diesel (2.9 CRDi)

DO-IT-YOURSELF MAINTENANCE
6-22
G350B01HP-GAT
BLEEDING THE FUEL SYSTEM
(FOR DIESEL ENGINE (2.9 CRDi))
The fuel system should be bled to remove air as described in the illustration if the fuel supply is exhausted during travel, when the fuel filter is replaced, or if the vehicle is not used for a long time.
1. Pump the hand prime pump with your hand for one minute(about 20~30 times).
2. Turn the ignition key to the "START" posi- tion and release it 2~3 times shortly until the engine starts.
NOTE:Do not hold the ignition key in the "START"position for more than 15 seconds. Doing so may cause the engine and the injection pump to damage.
G350A01HP
E090A02HP
2. Operate the hand pump slowly 6 or 7 times in order to force the water out through the drain plug.
3. Tighten the drain plug when water no longer comes out.
4. Loosen the air bleed bolt and bleed the air. (Refer to "Bleeding the fuel system")
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 authorized HYUNDAI dealer.
WARNING:
(1) Do not smoke or have any other open flame near the vehicle while bleeding thefuel system.
(2) Be sure to carefully wipe away any water drained out in this manner, because thefuel mixed in the water might be ignited and result in a fire.
G300A01HP-GATREMOVAL OF WATER FROM THE FUEL FILTER (FOR DIESEL ENGINE (2.5 TCI))
E100A01HP
If the fuel filter warning lamp illuminates during driving, it indicates that water has accumulated in the fuel filter. If this occurs, remove the water as described below.
1. Loosen the drain plug at the bottom of the fuel filter.
(2) Be sure to carefully clean away any fuel
which spilled onto nearby parts coming out of the air bleed bolt, because such
accumulations of fuel might ignite andcause a fire.

DO-IT-YOURSELF MAINTENANCE 6-23
G260A01HP-GAT REPLACING HEADLIGHT BULBSBefore attempting to replace a headlight bulb, be sure the switch is turned to the "OFF" position. The next paragraph shows how to reach theheadlight bulbs so they may be changed. Be sure to replace the burned-out bulb with one of the same number and wattage rating.
WARNING:Be sure to carefully wipe away any waterdrained out in this manner, because the fuel mixed in the water might be ignited and result in a fire. NOTE: The driver's side headlight bulb can be changed after lifting the engine coolant res- ervoir by hand. CAUTION: Keep the lamps out of contact with petro-leum product, such as oil, gasoline, etc.
G260A01HP
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 headlight.
4. Push the bulb spring for removing the head-
light bulb.
5. Remove the protective cap from the re- placement bulb and install the new bulb bymatching the plastic base with the headlight hole. Retighten the bulb spring and recon- nect the power cord.
6. Use the protective cap and carton to dis- pose of the old bulb.
7. Check for proper headlight aim. G270A02Y-AAT HEADLIGHT BULB
G270A01HP
G300B01HP-GAT REMOVAL OF WATER FROM THE FUEL FILTER
(FOR DIESEL ENGINE (2.9 CRDi))
G300A01HP
If the fuel filter warning lamp illuminates during driving, it indicates that water has accumulated in the fuel filter. If this occurs, remove the water as described below.
1. Loosen the drain plug at the bottom of the fuel filter.
2. Tighten the drain plug when water no longer
comes out.
3. 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 authorizedHYUNDAI dealer.