maintenance Hyundai Coupe 2002 Owner's Guide

OWNER MAINTENANCE 6-13
WARNING: Brake fluid is hygroscopic and should never be stored in an unsealed container. The pres- ence of water in the braking system will causevapour locks and increase the possibility of brake fade along with promoting corrosion within the braking system. The brake fluid must be changed at the specified time or mileage interval to ensure continued safe operation of the system. Brake fluid will cause rapid and serious damage to paintwork. If accidental spillage occurs, the affected area must be rinsed with water immediately. Do not allow brake fluid to come into contact with the eyes or to be ingested and ensure that fluid is safely stored away form the reach of children. SG130A1-C CHECKING THE CLUTCH FLUID (Not all models)To Check the Clutch Fluid The clutch fluid level in the master cylinder should be checked when performing other under bonnet checks. The system should be checked for leak- age at the same time. Ensure that the clutch fluid level is always be- tween 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.
SG130B2-E Adding Fluid Recommended brake fluid conforming to DOT 3 or DOT 4 should be used. The reservoir cap must be fully tightened to avoid contamination from foreign matter or moisture. CAUTION: Brake fluid is hygroscopic and should never be stored in an unsealed container. Do not allow petroleum base fluid to contaminate the brake fluid since damage to the rubber seals of the system may result. WARNING: Brake fluid will cause rapid and serious dam- age to paintwork. If accidental spillage oc- curs, the affected area must be rinsed with water immediately. Do not allow brake fluid to come into contact with the eyes or to be ingested and ensure that fluid is safely stored away form the reach of children. SG140A1-E AIR CONDITIONING SYSTEM MAINTENANCE Condenser Ensure that the condenser is periodically in- spected and that accumulations of dirt, dead insects and leaves etc, are removed to ensure that the efficiency of the system is not impaired. Care must be exercised to ensure that the con- denser fins are not damaged during cleaning.
HGK215
HGK216-D

OWNER MAINTENANCE
6-14
SG140B1-E Compressor Drive Belt The air conditioning compressor drive belt should be checked to ensure freedom from damage or excessive wear and correct tension. The belt tension is correct when the belt deflects by about 0.3 inches (8 mm) when a force of 98 N is applied to the belt halfway between the compressor and crankshaft pulleys. Adjustment of the belt should be entrusted to a Hyundai dealer.
SG140C1-E Checking the Refrigerant
1. Start the engine and run at idle for several
minutes with the refrigeration system running at the coldest setting.
2. Open the bonnet and inspect the sight glass on the top of the receiver dryer.
3. If the refrigerant charge is insufficient, a flow of bubbles will be observed through the sight glass.
4. If the refrigerant charge is satisfactory, no
bubbles will be observed through the sight glass.
CAUTION: Running the air conditioning system with a low refrigerant level may damage the com- pressor.
A/C
CRANK PULLEY
TENSION PULLEY 0.315 in. (8mm)
G140D01GK
V6
DOHC VVT
Auto tensioner
Eng.pulleyCOMP
SG140D1-E Off Season Maintenance The air conditioning must be run for ten minutes or so weekly during periods when the system would not normally be used to ensure that the compressor and seals are lubricated. If this pre- caution is not observed the compressor seals may become stuck to the compressor shaft and damaged when the system is next used resulting in a loss of refrigerant and damage to the com- pressor. B760B01GK-GAT Replacement of air filter:
1. Remove the taping screws on the downside
of the glove box.
HGK250
HGK251
2. Open the glove box and remove the taping
screws on the upside of the glove box.
3. Remove the filter cover and replace the filter.

OWNER MAINTENANCE 6-15
HGK253
HGK254
4. Installation is the reverse order of disassem- bly. CAUTION:
o Replace the filter every 10,000 miles or
once a year. If the car is being driven insevere conditions such as dusty, rough roads, more frequent air filter inspections and changes are required.
o When the air flow rate is suddenly de-
creased, it must be checked at an autho- rized dealer.
SG150A1-E STEERING WHEEL FREEPLAY Steering wheel freeplay should be checked to ensure that the specified value is not exceeded.HGK218
SG160A1-E CLUTCH PEDAL FREEPLAY
SSA6160A
0.24 ~ 0.51 in. (6 ~ 13 mm)
The clutch pedal freeplay should be checked against the specified value. If the freeplay is not correct, the clutch should be adjusted by a Hyundai dealer.
1.18in. (30 mm)

OWNER MAINTENANCE
6-16
SG170A1-E BRAKE PEDAL FREEPLAY
SSA6170A
0.12 ~ 0.31 in. (3 ~ 8 mm)
The brake pedal freeplay should be checked with the engine turned off. The pedal to floor clear-ance should be checked with the engine running and a load of 490 N applied to the pedal. If either value is incorrect, the necessary adjustment should be performed by a Hyundai dealer. Pedal to floor clearance: 1.97 in. (50 mm) SG190A1-E DRIVE BELTS
The various engine drive belts must be checked for condition, tension and freedom from damageand excessive wear. The tension of a new belt must be checked after thirty minutes running following fitment of the new belt to allow for the initial belt stretch. SG200A1-E FUSIBLE LINKS
AS60310A
Melted
Good
The fusible link prevents damage to the wiring harness in the event of an electrical systemmalfunction. Failure of a fusiblelink is indicative of a serious overload condition having occurred and therefore the electrical system should be checked by a Hyundai dealer before a replace- ment link is fitted. WARNING: Under no circumstances should a fusible link be replaced with anything other than a new link of the same rating. The use of higher rated links or other means of connecting the circuit will create a potential fire hazard.G190A01GK
V6 DOHC VVT
Water Pump Pulley
Generator Pulley
Crankshaft Pulley 0.2 ~ 0.24 in. (5.1~6 mm)
Power steering
Auto tensioner
GeneratorEng.pulleyCOMP

OWNER MAINTENANCE 6-17
SG200B2-E INDIVIDUAL CIRCUIT FUSES The fuse box containing the individual circuit fuses is located on the lower portion of the dashboard adjacent to the bonnet release. The fuse box cover is removed by pushing lightly and then releasing the lid. A fuse rating grid will be found on the reverse side of the cover. In the event of fuse failure, the fuse should be replaced with one of equivalent rating. A fuse removal tool is provided within the fuse box to facilitate re- placement. In the event of a replacement fuse failing shortly after installation a malfunction within the circuit protected by that fuse is indicated. The circuit should be checked by a Hyundai dealer at the first available opportunity.
AXA6201B
WARNING: The use of replacement fuses having a higher rating than specified or other means of con- necting the circuit will create a potential fire hazard. NOTE: See page 6-20 for the fuse panel descriptions. SG210A1-E BATTERY MAINTENANCE WARNING: Motor vehicle batteries contain sulphuric acid which is corrosive and poisonous. Hydrogen gas is emitted from the battery which is ex- plosive when combined with oxygen. The following precautions must be strictly ob- served to avoid personal injury or damage to the vehicle.
HGK185-D
SG220A1-E ELECTRIC COOLING FANSWARNING: The cooling fan is controlled by engine cool- ant temperature and may sometimes operate 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 engine coolant temperature decreases, the fan will automati- cally shut off. This is a normal condition.
o If battery electrolyte is spilled onto skin or into
eyes, the effected area must be flushed with copious amounts of water and medical assis- tance sought.
o If battery electrolyte is ingested, copious
amounts of water or milk followed by an ant- acid (raw egg or milk of magnesia) must be drunk. Vomiting should not be induced and medical assistance must be sought.
o Batteries must only be charged in well venti- lated areas from which naked lights or sources 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.

OWNER MAINTENANCE
6-18 NOTE: Grinding noise from power steering pump may be heard immediately after the engine is started in extremely cold condition (below -20°C). In this case, if the noise stops during warm up, there is no abnormal function in the system. This is due to a power steering fluid characteristic in extremely cold conditions. FLUID RECOMMENDATION
Only automatic transmission fluid meeting the specification of PSF-3 should be used in the power steering system.
SG230A1-E POWER STEERING FLUID LEVEL The power steering fluid level should be checked daily. To check the power steering fluid level, be sure the ignition is "OFF", then check to make certain that the power steering fluid level is between the "MAX" and "MIN" level markings on the fluid reservoir.
SG250A2-E REPLACING HEADLIGHT BULBS In the event of bulb failure being experienced, ensure that the relative lighting circuit is turned off prior to attempting to replace the bulb. The illustrations on the following pharagraph will as- sist in locating and removing the headlight bulbs. Ensure that the replacement bulb has the same cap configuration and wattage as the original.
SG230B1-E POWER STEERING HOSES Power steering hoses should be checked for damage, deterioration and leakage at each ser- vice.
The engine cooling fan should operate before the temperature gauge reaches the upper portion of the scale and the condenser fan should operate whenever the air conditioning is in use.
HGK214 G270A02A-GAT HEADLIGHT BULB Replacement instructions:
HGK225
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. Remove the dust cover.
5. Push the bulb spring for removing the head- light bulb.
6. Remove the protective cap from the replace- ment bulb and install the new bulb by match-ing the plastic base with the headlight hole. Install the dust cover after retightening the bulb spring and reconnect the power cord.
7. Use the protective cap and carton to dispose
of the old bulb.
8. Check for proper headlight aim.High Beam Low Beam
Turn signal Light

OWNER MAINTENANCE 6-19
G290A01GK-EAT HEADLIGHT AIMING ADJUSTMENT
Before performing aiming adjustment, make sure of the following.
1. Keep all tyres inflated to the correct pressure.
2. Place the vehicle on level ground and press
the front bumper & rear bumper down severaltimes. Place vehicle at a distance of 118.1 in. (3m) from the test wall.
3. See that the vehicle is unloaded (except for
full levels of coolant, engine oil and fuel, and spare tyres, jack, and tools).
4. Clean the head lights lens and turn on the headlight.
5. Open the boot.
6. Draw the vertical line (through the centre of each headlight beam pattern) and the hori-zontal line (through the centre of each head- light beam pattern) on the aiming screen. And then, draw the parallel line at 1.18 in. (30 mm) under the horizontal line.
WARNING:The halogen bulb contains gas under pres- sure and if impacted could shatter, resulting in flying fragments. Always wear eye protec- tion when servicing the bulb. Protect the bulb against abrasions or scratches and against liquids when lighted. Turn on the bulb only when installed in a headlight. Replace the headlight if damaged or cracked. Keep the bulb out of the reach of children and dispose of the used bulb with care.
Vertical aiming
G290A01GK
Horizontal aiming
Low Beam
Vertical aiming
G290A02GK
Horizontal aiming
High Beam
7. Adjust each cut-off line of the low beam to the
parallel line with a phillips screwdriver - VER- TICAL AIMING.
8. Adjust each cut-off line of the low beam to the each vertical line with a phillips screwdriver - HORIZONTAL AIMING.
G290B01GK-EAT Adjustment After Headlight Assembly Replacement
G290B02Y
Vertical line
Cut-off line Ground line
Horizontal line
LW
H
H "P"1.18 in.(30 mm)
If the vehicle has had front body repair and the headlight assembly has been replaced, the head- light aiming should be checked using the aiming screen as shown in the illustration. Turn on the headlight switch.
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 illustration.
2. Dotted lines in the illustration show centre of headlights.

OWNER MAINTENANCE
6-20
SPECIFICATION: "H" Horizontal centre line of headlights from ground: Low Beam: 26.7 in. (679mm) High Beam: 26.5 in. (672mm) "W" Distance between each headlight centre : Low Beam: 47.3 in. (1,202mm) High Beam: 38.0 in. (966mm) "L" Distance between the headlights and the wall that the lights are tested against : 118.11 in. (3,000 mm)

OWNER MAINTENANCE 6-21
Wattage
55/55 10
5
51 21
55
G280A02GK-EAT
Part Name
Head Light (High/Low) Map Light Front Position Light Front Fog Light (Not all models)Front Turn Signal Light Front Door Edge Warning Light Luggage Compartment Light
No.
12 3 45 6 7 No.
8 9
10 11 12 13 Part Name
High Mounted Without spoiler
Stop LIght With spoiler Rear Turn Signal Light
Combination Stop/Tail Light Back-up Light
License Plate LightRear Fog Light (Not all models)Wattage
2.4W (LED) 3.5W (LED) 21
21/5 215
21
5111213346
HGK035A
1182
(High) (Low)
109
7

OWNER MAINTENANCE
6-22
G200C01GK-GAT FUSE PANEL DESCRIPTION Engine Compartment HGK205-EPROTECTED COMPONENTS
GeneratorGeneratorCondenser FanRadiator FanEngine Control, ECM. ATM ControlIgnition, Start Relay ABSABSBlowerInjector O 2 Sensor, ECM
DRL Front fog LightTCM, ECMHorn. A/conditionerHead Light (High) Head Light (LOW)
FUSE RATING
100A50A30A30A30A30A 30A30A 30A 15A10A15A15A 10A 15A15A15A
DESCRIPTION
BATT BATT
COND RADECUIGN
ABS 1 ABS 2
BLOWER
INJ
SNSR DRL
F/FOG ECU
HORN,A/CON H/LP (H1)
H/LP (LO)
NOTE:
Not all fuse panel descriptions in this manual may be applicable
to your vehicle. It is accurate at the time of printing. When youinspect the fuse box on you r vehicle, refer to the fuse box label.
Not all models