steering Hyundai Atos 2002 Service Manual

DO-IT-YOURSELF MAINTENANCE 6-13
ZG150A1-A
CHECKING STEERING WHEEL FREEPLAY
AS60260A
1.18 in. (30 mm)
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. ZG160A1-A CHECKING CLUTCH PEDAL FREEPLAY
SSA6160A
0.24~0.51 in. (6 ~ 13 mm)
With the engine off, press lightly on the clutch pedal until you feel a change in resistance. Thisis the clutch pedal freeplay. The freeplay shouldbe within the limits specified in the illustrationbelow. If it is not, have it inspected by yourHyundai dealer and adjusted or repaired if nec-essary.
SSA6170A
0.12 ~ 0.31 in. (3 ~ 8 mm)
ZG170A1-A
CHECKING BRAKE PEDAL FREEPLAY
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 below. If it is not, have itinspected by your Hyundai dealer and adjustedor repaired if necessary.

DO-IT-YOURSELF MAINTENANCE
6-16 G270A01X-GAT
HEADLIGHT BULB
G270A01X
Replacement instructions:
1. Allow the bulb to cool. Wear eye protection.
2. Always grasp the bulb by its base, avoid touching the glass.
3. Disconnect the connector, then remove the dust cover.
4. Push the bulb spring for removing the head- light bulb.
5. Remove the headlight bulb. If the bulb is burned out, replace it with the same watt- age.
6. Installation is the reverse order of the re- moval.
7. Use the protective cap and carton to promptly dispose of the old bulb.
8. Check for proper headlight aim.
noise stops during warm up, there is no
abnormal function in the system. This is dueto a power steering fluid characteristic inextremely cold conditions.
Recommended Fluid Use PSF-3 type fluid. NOTE: Do not start the engine when the power
steering oil reservoir is empty. ZG230B1-E
POWER STEERING HOSES It is suggested that you check the power steering hose connections for fluid leakage at those inter-vals specified in the vehicle maintenance sched-ule in Section 5.The power steering hoses should be replaced ifthere is severe surface cracking, pulling, scuff-ing or worn spots. Deterioration of the hose couldcause premature failure.
G260A01A-AAT
REPLACING LIGHT BULBS Before attempting to replace a light bulb, be
sure the switch is turned to the "OFF" position.
The drawings show how to reach light bulbs sothey may be changed. Be sure to replace the
burned-out bulb with one of the same numberand wattage rating.
G220C01A-AAT
Checking Condenser Cooling Fan
The condenser cooling fan should come on
automatically whenever the air conditioning is in operation.
G230A03A-GAT
POWER STEERING FLUID LEVEL
G230A01X
The power steering fluid level should be checked
regularly.
To check the power steering fluid level, be sure
the ignition is "OFF", then check to make cer- tain that the power steering fluid level is be-
tween the "MAX" and "MIN" level markings onthe 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 -4°F(-20°C)). In this case, if the

CONSUMER INFORMATION 8-1
ZI010B1-A Engine Number
ZI010A1-E VEHICLE IDENTIFICATIONNUMBER (VIN)
ZI000A1-E
8. CONSUMER IN
FORMATION
I010A01A
The vehicle identification number (VIN) is the number used in registering your car and in alllegal matters pertaining to its ownership, etc.
o On the identification plate attached to theengine side of the firewall between the en- gine and passenger compartments.
I010B01A
The engine number is stamped on the engine block as shown in the drawing. ZI010C1-E TYRE INFORMATIONThe tires supplied on your new Hyundai are chosen to provide the best performance fornormal driving. XI020A1-E TYRE PRESSURES
XV80030E
In modern high-speed motoring, correct tyre pressures are vitally important.Incorrect pressures can reduce adhesion, af-fect the steering, and cause excessive tyrewear. Check the pressures before you start atrip, when tyres are cold. If the pressures aremeasured when the tyres are warm, a higherreading will be obtained.
8
4.0BX13 4.5JX13 5.0JX13 TIRE
SIZE PRESSURE. kPa (PSI)
155/70R13155/70R13 175/60R13 REAR
207(30) 207(30)207(30) FRONT
221(32)221(32) 221(32)
UP TO 2
PERSONS UP TO MAX.
LOAD
REAR
221(32) 221(32) 221(32)
FRONT 207(30)207(30)207(30)
RIM
SIZE

VEHICLE SPECIFICATIONS 9-1
Litres
35 J040A01X-GAT ELECTRICAL
Battery Alternator Starting motor
MF 12V 40AH
13.5V 60A
0.8 KW
J050A02X-GAT BRAKE
Dual hydraulic with brake booster Ventilated disc Drum Cable operated on rear wheel
J060A01X-EAT FUEL SYSTEM
lmp.gal 7.7
J020A01X-EAT POWER STEERING
Type Wheel free play Rack stroke Oil pump type Rack and pinion0 ~ 1.181 in. (0 ~ 30 mm) 5.354 in. (136 mm) Vane type
ZJ000A1-A
9. VEHICLE SPECIFICATIONS J030A02X-EAT TYRE
155/70 R 13 175/60 R 13 Full size spare
Standard Option Spare
J010A02X-EAT MEASUREMENT
137.6 (3495)58.9 (1495) 63.6 (1615) 62.2 (1580) 93.7 (2380) 51.8 (1315) 51.2 (1300)Overall length Overall width Overall height (unladen) Wheel base Wheel tread
in. (mm)
ATOZ AMICA
Front Rear
Fuel tank Capacity Type Front brake type Rear brake type Parking brake
9

VEHICLE SPECIFICATIONS 9-3
Oil & Coolant Standard
SAE 20W-40, 20W-50 (ABOVE -14°F)
API SG SAE 15W-40, 15W-50 (ABOVE 5°F)
OR SAE 10W-30 (-13°F ~ 104°F)
ABOVE SAE 10W-40, 10W-50 (ABOVE -13°F) SAE 5W-20 *1, *2 (BELOW 14°F)SAE 5W-30 *1 (BELOW 50°F)SAE 5W-40 *1 (BELOW 68°F)
*1. Restricted by driving condition and dealing area
*2. Not recommended for sustained high speed vehicle operation Normal driving conditionSevere driving conditionHYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)ESSO JWS3314PSF-3 DOT 3, DOT 4 or equivalent Ethylene glycol base for aluminum radiator
Item
Engine Oil Engine oil consumption Transaxle Power steering Brake fluidEngine coolant Q'ty
2.72 lmp.qts (3.26 us-qts, 3.1 litres)
MAX. 1L / 1500 Km
MAX. 1L / 1000 Km
2.15 lmp.qts (2.58 us-qts, 2.45 litres)
4.56 lmp.qts (5.48 us-qts, 5.2 litres)As required As required
3.95 lmp.qts (4.74 us-qts, 4.5 litres)
J080A06X-EAT LUBRICATION CHART
Manual Auto

INDEX
10-2
FRONT FOG LIGHT
SWITCH ......................................................... 1-29
FUEL ECONOMY ............................................................................... 2-3
FUEL GAUGE .................................................................................. 1-20
FUEL RECOMMENDATIONS ........... ................................................. 1-1
FUSIBLE LINKS ............................................................................... 6-14
G GENERAL CHECKS .......................................................................... 6-2
H
HAZARD WARNING SYSTEM ........................................................ 1-24
HEADLIGHT BULB ........................................................................... 6-16
HEADLIGHT LEVELING DEVICE SYSTEM ....................................1-23
HEADRESTRAINT .............................................................................. 1-5
HEADLIGHT FLASH ER .................................................................... 1-22
HEADLIGHT SWITCH ...................................................................... 1-21
HEATED REAR WINDOW ................... ............................................1-24
HEATING AND VENTILATION ........................................................ 1-32
HIGH AND LOW BEAM ................................................................... 1-21
HIGH-MOUNTED REAR STOPLIGHT .............................................1-27
HORN ............................................................................................... 1-32
IIF THE ENGINE CANNOT BE CRANKED ........................................ 3-1
IF THE ENGINE OVERHEATS .......................................................... 3-2
IF THE ENGINE WILL NOT START .................................................. 3-1
IGNITION SWITCH ............................................................................. 2-2
IMMOBILIZER SYSTEM ..................................................................... 1-2INDIVIDUAL CIRCUIT FUSES ......................................................... 6-15
INSTRUMENT CLUSTER AND INDICATOR ..................................1-17INSTRUMENTS AND CONTROLS
..................................................1-16
INTERIOR LIGHT ............................................................................. 1-25
JJUMP STARTI NG ........................................................................ 3-1~3-2
KKEY POSITIONS ................................................................................ 2-2
KEYS .................................................................................................. 1-2 L LIGHT BULBS .................................................................................. 6-16
LIMP HOME PROCEDURES ............................................................. 1-2
LOW FUEL LEVEL WARNING LAMP .............................................1-19
M
MAINTENANCE AND SERVICING REQUIREMENTS ..................... 5-1
MAINTENANCE UNDER SEVERE USAGE CONDITIONS .............. 5-4
MANUAL TRANSAXLE LUBRICANT ................................................. 6-9
MANUAL TRANSAXLE ...................................................................... 2-4
MULTI FUNCTION SWITCH ................................. ...........................1-21
OODOMETER ..................................................................................... 1-21
OIL PRESSURE WARNING LIGHT ................................................. 1-18
OUTSIDE REAR VIEW MIRROR ....................................................1-25
PPARKING BRAKE ............................................................................ 1-26
POWER STEERING FLUID LEVEL ................................................. 6-16

INDEX10-3
POWER STEER
ING HOSES ........................................................... 6-16
POWER WINDOWS ........................................................................... 1-6
R
REAR FOG LIGHT SWITCH ............................................................ 1-29
REAR WINDOW WIPER AND WASHER ........................................1-23
REMOTE FUEL FILLER LID RELEASE ..........................................1-29
REMOTE TAIL GATE RELEASE ..................................................... 1-29
RUNNING IN ...................................................................................... 1-1
S SCHEDULED MAINTENANCE ................................................. 5-2 ~ 5-3
SEAT BELT PRECAUTIONS ............................................................. 1-7
SEAT BELTS ........................................................................... 1-8 ~ 1-10
SNOW TYRES ................................................................................... 8-1
SPARE TYRE .............................................................................. 3-3, 8-3
SPARK PLUG RE PLACEMENT........................................................ 6-7
SPECIFIATIONS .......................................................................... 9-1, 9-3
SPEEDOMETER .............................................................................. 1-21
SRS AIRBAG SYSTEM ......................................................... 1-12 ~ 1-15
STARTING .......................................................................................... 2-3
STEERING WHEEL FREEPLAY ..................................................... 6-13
STEREO RADIO AND CASSETTE TAPE PLAYER OPERATION (H900) ........................................................ 1-42 ~ 1-44
STEREO RADIO OPERATION (H922M) .............................. 1-45 ~ 1-46
STEREO RADIO OPERATION (HMR90) ............................. 1-40 ~ 1-41
STEREO SOUND SYSTEM .................................................. 1-38 ~ 1-39
SUN-VISOR ...................................................................................... 1-31
T TAIL GATE
....................................................................................... 1-28
TRAILER OR VEHICLE TOWING ........................................ 2-10 ~ 2-12
TRANSAXLE FLUID (AUTOMATIC) ..................................... 6-10 ~ 6-11
TYRE BALANCING ............................................................................ 8-2
TYRE INFORMATION ........................................................................ 8-1
TYRE PRESSURES ........................................................................... 8-1
TYRE REPLACEMEN T ...................................................................... 8-2
TYRE ROTATION .............................................................................. 8-2
V VEHICLE IDENTIFICATION NUMBER (VIN) .................................... 8-1
VEHICLE TOWING OR RECOVERY ................ .........................3-6~3-8
W WHEEL AND TYRE CHANGING ............................................... 3-3 ~3-6
WHEEL REPLACEMENT ................................................................... 8-2
WINDOW GLASS ............................................................................... 1-6
WINDSCREEN WIPER AND WASHER SWITCH ...........................1-22
WINDSHIELD WASHER OPERATION ............................................1-22
WINDSHIELD WIPER BLADES ......................................................... 6-9
WINTER MOTORING ......................................................................... 2-9