light Hyundai Atos 2002 Repair Manual

DO-IT-YOURSELF MAINTENANCE
6-2 ZG020B1-E
GENERAL CHECKS Engine Compartment
The following should be checked regularly:
o Engine oil level and condition
o Transaxle fluid level and condition
o Brake reservoir fluid level
o Engine coolant level
o Windscreen washer fluid level
o Accessory drive belt condition
o Coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level
o Tyre pressure and condition (including spare)
o Battery condition ZG020C1-A
Vehicle Exterior
The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut tightness
o Exhaust system condition
o Light condition and operation
o Windscreen glass condition
o Wiper blade condition
o Paint condition and corrosion
o Fluid leaks
o Door and hood lock condition o Air filter element condition G020C02X-GAT
Vehicle Interior
The following should be checked each time
when the vehicle is driven:
o Lights operation
o Windscreen wipers operation
o Horn operation
o Defroster, heating system operation (and air conditioning, if installed)
o Steering operation and condition
o Mirror condition and operation
o Turn signal operation
o Accelerator pedal operation
o Brake operation, including parking brake
o Manual transaxle operation, including clutch operation
o Automatic transaxle operation, including "Park" mechanism operation
o Seat control condition and operation
o Seat belt condition and operation
o Sunvisor operation
If you notice anything that does not operate
correctly or appear to be functioning correctly, inspect it carefully and seek assistance fromyour Hyundai dealer if service is needed. ZG030A1-A
CHECKING THE ENGINE OIL
Engine oil is essential to the performance andservice of the engine. It is suggested that youcheck the oil level at least once a week innormal use and more often if you are on a tripor driving in severe conditions. ZG030B1-E
Recommended Oil
SSA6030B°C °F -25-13 20W-40 20W-50
15W-40 15W-50
10W-30
10W-40 10W-50
5W-40
5W-30
5W-20
40104
2068
1050
032
-15 5 -10-14
SH, SG or SG/CD (API) multi-grade and fuel efficient oil is recommended. NOTE: SAE 5W-20 is not recommended for sus-tained high speed vehicle operation.

DO-IT-YOURSELF MAINTENANCE
6-8
G070A01X
(1)
SSA6060A
0.039 ~ 0.043 in. (1.0 ~ 1.1 mm)
ZG060A2-E Recommended Spark Plugs (Unleaded) NOTE: When replacing the spark plug, always use
the genuine parts recommended. G070A01X-GAT
CHANGING THE AIR CLEANER FIL- TER
To change the filter, loosen the clamps (1) on 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. CAUTION: Operating your vehicle without a proper air filter in place can result in excessive enginewear.
G060C02A
Only the correct grade of spark plug should be used. Use of an incorrect grade mayresult in serious engine damage. Prior to installing a spark plug, the gap between the centre and outer electrodesmust be checked and adjusted as neces-sary. Adjustment is facilitated by bending the outer electrode towards or away from the centreelectrode. Under no circumstances shouldattempts be made to adjust the position ofthe centre electrode.
3. Insert the spark plug into the cylinder head and screw by and until the plug contacts theseating area. Tighten the plug with the sock-et by a further 1/2 to 3/4 of a turn only.
4. Replace the plug lead ensuring that the cap is pushed firmly into place. Confirm that thecap is correctly seated by lightly pullingupon it.G060C03A CHAMPION : RC9YC4
RC10YC4
NGK : BKR5ES-11

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 6-15
DG200B2-E
INDIVIDUAL CIRCUIT FUSES
XV60320E
The fuse box containing the individual circuit fuses is located on the lower portion of thedashboard adjacent to the bonnet release. Thefuse box cover is opened by sliding the knob onthe cover to the right. A fuse rating grid will befound on the reverse side of the cover. In theevent of fuse failure, the fuse should be re-placed with one of equivalent rating. A fuseremoval tool is provided within the fuse box tofacilitate replacement. In the event of a replacement fuse failing shortly after installation a malfunction within the circuitprotected by that fuse is indicated. The circuitshould be checked by a Hyundai dealer at thefirst available opportunity.
SSA6201B
WARNING: The use of replacement fuses having a high-
er rating than specified or other means of connecting the circuit will create a potentialfire hazard.
DG210A2-E
BATTERY MAINTENANCE WARNING:
Motor vehicle batteries contain sulphuric
acid which is corrosive and poisonous. Hy- drogen gas is emitted from the battery whichis explosive when combined with oxygen.The following precautions must be strictlyobserved to avoid personal injury or dam-age to the vehicle.
o If battery electrolyte is spilled onto skin or into eyes, the effected area must be flushed with copious amounts of water and medicalassistance sought. o If battery electrolyte is ingested, copious
amounts of water or milk followed by anantacid (raw egg or milk of magnesia) mustbe drunk. Vomiting should not be inducedand medical assistance must be sought.
o Batteries must only be charged in well ven- tilated areas from which naked lights orsources of sparks are excluded.
o Ensure that children, pets or other unautho- rized persons are kept away from batteries.
o Do not allow anything to bridge the positive (+)and negative (-) terminals of the battery.
o Never invert the battery.
The battery fitted during production is of the“Maintenance Free” type. 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 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. G220B01A-AAT
Checking Engine Cooling Fan The engine cooling fan should come on auto- matically if the engine coolant temperature ishigh.

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

DO-IT-YOURSELF MAINTENANCE 6-17
WARNING: The halogen bulb contains gas under pres-
sure and if impacted could shatter, and re- sulting in flying fragments. Always wear eye
protection when servicing the bulb. Protectthe bulb against abrasions or scratches andagainst liquids when lighted. Turn on thebulb only when installing in a headlight.Replace the headlight if damaged or cracked.Keep the bulb out of the reach of childrenand dispose of the used bulb with care.
G290A01X-EAT
HEADLIGHT AIMING ADJUSTMENT
G290A01V
Before performing aiming adjustment, make sure
of the following.
Vertical aiming
1. Keep all tires inflated to the correct pres- sure.
2. Place the vehicle on level ground and press the front bumper & rear bumper down sev- eral times.
3. See that the vehicle is unloaded (except for full levels of coolant, engine oil and fuel, andspare tire, jack, and tools). Have the driveror equivalent weight placed in driver's seat.
4. Clean the head lights lens and turn on the headlight (Low beam).
5. Open the bonnet.
6. Draw the vertical line (through the center of each headlight) and the horizontal line(through the centre of each headlight) on theaiming screen.
1) Horizontal line dimension from ground:25.43 in. (646 mm)
2) Distance between each vertical line: 38.89 in. (988 mm)And then, draw the parallel line at 1.18 in. (30 mm) place 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 the each vertical line with a phillips screw-driver - HORIZONTAL AIMING. G290B01X-EAT
Adjustment After Headlight Assembly Replacement
If the vehicle has had front body repair and the headlight assembly has been replaced, theheadlight aiming should be checked using theaiming screen as shown in the illustration. Turnon the headlight switch. (Low Beam Position)
1. Adjust headlights so that main axis of light is parallel to centre line of the body and isaligned with point "P" shown in the illustra-tion.
2. Dotted lines in the illustration show centre of headlights. G290B01S-DAG
Horizontal lineVertical line
W
0.59 in.
"P" 1.18 in.
Cut-off line
Ground line H
H L

DO-IT-YOURSELF MAINTENANCE
6-18 "H"; Horizontal centre line of headlights from ground: 25.43 in. (646 mm) "W"; Distance between each headlight centre: 38.89 in. (988 mm) "L"; Distance between the headlights and the wall that the lights are tested against: 118.11 in. (3,000 mm).

DO-IT-YOURSELF MAINTENANCE 6-19
No.
1 23456 7
G280A01X-GAT
(ATOZ)
Part Name
Front Fog Light (Not all models) HeadlightFront Position LightFront Turn Signal LightSide Repeater Light (Not all models)Interior Light HIgh Mounted Rear Stop Light Wattage
55
60/55 5
21
5 8
21 No.
89
1011 Wattage
55
21 21
21/5
21Part Name
Luggage Compartment Light License Plate LightRear Fog LightRear Combination LightTurn Signal LightStop/Tail Light Back-up Light
G280A02X
61179
14325108

DO-IT-YOURSELF MAINTENANCE
6-20 No.
1 2 3 4567
G280A01V-GAT
(AMICA)
Part Name
Front Fog Light (Not all models) Headlight Front Position Light Front Turn Signal LightSide Repeater Light (Not all models)Interior LightHIgh Mounted Rear Stop Light Wattage
55
60/55
5
21 58
2.6 No.
89
1011 Wattage
55
21 21
21/5 21Part Name
Luggage Compartment Light License Plate LightRear Fog LightRear Combination LightTurn Signal Light Stop/Tail Light Back-up Light
G280A03V
6119
14325108
7

INDEX10-1
A ABS SYSTEM
..................................................................................... 2-7
ADJUSTABLE FRONT SEATS .......................................................... 1-5
AIR CLEANER FILTER ...................................................................... 6-8
AIR CONDITIONER CARE .............................................................. 6-12
AIR CONDITIONING SWITCH ......................................................... 1-36
AIR CONDITIONING OPERATION .................................................1-37
ANTENNA ......................................................................................... 1-52
APPEARANCE CARE ....... ........................................................ 4-1 ~ 4-2
ASHTRAY ......................................................................................... 1-25
AUDIO FAULT CODE ...................................................................... 1-49
AUTOMATIC TRANSAXLE ......................... .............................. 2-5 ~ 2-6
BBATTERY MAINTENANCE .............................................................. 6-15
BEFORE STARTING THE ENGINE .................................................. 2-2
BONNET RELEASE ......................................................................... 1-30
BRAKE CIRCUIT FAILURE WARNING LAMP ................................1-18
BRAKE PEDAL CLEARANCE ......................................................... 6-14
BRAKE PEDAL FREEPLAY ............................................................. 6-13
BRAKES ........................................................................................... 6-11
C
CARE OF SEAT BELTS .................................................................... 1-7
CARE OF CASSETTE TAPE ................................................ 1-50 ~ 1-51
CARE OF DISC ................................................................................ 1-50
CATALYTIC CONVERTER (For MFI ) ................................................ 7-1 CENTRAL DOOR LOCKING
SYSTEM ............................................. 1-7
CHANGING THE OIL AND FILTER .................. ....................... 6-4 ~ 6-5
CHARGING WARNING LIGHT ........................................................ 1-19
CHILD PROTECTOR REAR DOOR LOCKS .................................... 1-4
CHILD RESTRAINT SYSTEM ............................................... 1-10 ~ 1-11
CIGAR LIGHTER .............................................................................. 1-24
CLOCK .............................................................................................. 1-24
CLUTCH PEDAL FREEPLAY .......................................................... 6-13
COMPACT DISK PLAYER OPERATION (H922M) .............. 1-47 ~ 1-48
COMPRESSOR DRIVE BELT ......................................................... 6-12
COOLING FANS .............................................................................. 6-15
D
DAY-NIGHT REAR VIEW MIRROR .................................................1-26
DOOR LOCKS .................................................................................... 1-3DRIVE BELTS .................................................................................. 6-14
DRIVING FOR ECONOMY ................................................................ 2-8
EEFFECTIVE BRAKING ....................................................................... 2-7
EMERGENCY T OWING ..................................................................... 3-8
EMISSION CONTROL SYSTEM ......... .............................................. 7-1
ENGINE COMPARTMENT (For MFI Engine) .................................... 6-1
ENGINE COOLANT ........................................................................... 6-5
ENGINE COOLANT TEMPERATURE GAUGE ...............................1-20
ENGINE OIL CONSUMPTION ........................................................... 6-3
F
FILLING THE WASHER RESERVOIR .............................................. 6-9
FOLDING REAR SEAT BACK AND SEAT CUSHION ...................1-27
FOLDING THE OUTSIDE REAR VIEW MIRRORS ........................1-26
ZK000A1-E 10. INDEX
10