radiator Hyundai Coupe 2003 User Guide

DO-IT-YOURSELF MAINTENANCE
6-14
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 (0.315inches). If the belt is too loose, have it adjustedby your Hyundai dealer. A/C
CRANK PULLEY
TENSION PULLEY 8mm (0.315 in.)
G140D01GK
V6
DOHC
Auto tensioner
Eng.pulley COMP
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 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.
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 your eyes. 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 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 avoidbending the cooling fans.

DO-IT-YOURSELF MAINTENANCE 6-23
G200C01GK-GAT
FUSE PANEL DESCRIPTION Engine Compartment
HGK205-EPROTECTED COMPONENTS
Generator Generator Condenser Fan Radiator FanEngine Control, ECM. ATM ControlIgnition, Start RelayABSABS Blower InjectorO 2 Sensor, ECM
DRL
Front Fog Light TCM, ECM
Horn. A/ConditionerHead Light (High)Head Light (LOW)
FUSE RATING
120A50A30A 30A 30A30A30A30A30A 15A 10A15A15A10A15A 15A 15A
DESCRIPTION
BATTBATT
COND RADECU
IGN
ABS 1ABS 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 you inspect the fuse
box on your vehicle, refer to the fuse box label.
If installed

VEHICLE SPECIFICATIONS 9-3
Oil & Grease Standard
1.6L / 2.7L API SG or SAE 20W-40, 20W-50 (ABOVE -10°C)
ABOVE SAE 15W-40, 15W-50 (ABOVE -15°C) SAE 10W-30 (-25°C ~ 40°C) SAE 10W-40, 10W-50 (ABOVE -25°C)SAE 5W-20 *1, *2 (BELOW -10°C) SAE 5W-30 *1 (BELOW 10°C) SAE 5W-40 *1 (BELOW 20°C)
2.0L API SH or SAE 15W- 40 (ABOVE -10°C)
ABOVE, SAE 10W-30 (-25°C ~ 40°C)
ILSAC GF-1 SAE 10W-40 (ABOVE -25°C)
or ABOVE SAE 5W-20 (BELOW -10°C) *1, *2
SAE 5W-30 (BELOW 10°C) *1SAE 5W-40 (BELOW 20°C) *1
*1. Restricted to driving condition and vehicle destination*2. Not recommended for sustained high speed vehicle operationNormal driving condition Severe driving condition HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)DIAMOND ATF SP- III or SK ATF SP- III
PSF-3DOT 3 or DOT 4 equivalent Ethylene glycol base for aluminium radiator
J080A03GK-GAT
LUBRICATION CHART
Item
Engine Oil Engine Oil Consumption TransaxlePower Steering Brake Fluid CoolantQ'ty (liter) (us.qts., Imp.qts.)
Engine Oil: 1.6 L : 3.3 (3.5, 2.9)2.0 L : 3.85 (4.07, 3.39) 2.7 L : 4.5 (4.76, 4.0) Oil Pan: 1.6 L : 3.0 (3.17, 2.64) (MAX)
2.0 (2.11, 1.76) (MIN)
2.0 L : 3.55 (3.75, 3.12) (MAX) 2.6 (2.75, 3.3) (MIN)
2.7 L : 4.2 (4.44, 3.7) (MAX) 3.4 (3.59, 3) (MIN)
Oil Filter : 0.3 (0.32, 0.26) MAX. 1L / 1500 Km MAX. 1L / 1000 Km5 speed:2.15(2.27, 1.86) 6 speed:2.2(2.32, 1.94)
7.8 (8.2, 6.9) As requiredAs required 1.6L/2.0L : 7.0 (7.4, 6.2) 2.7L : 8.0 (8.5, 7.0)
Manual Auto

CONTROLS AND EQUIPMENT
1- 30 SB215F1-E TACHOMETER
SB215B1-E ENGINE COOLANT TEMPERATURE GAUGE engine is hot may cause hot water and steam to be ejected from the radiator resulting inburns and scalding. The radiator cap mustonly be removed when the engine has cooled.Do not add cold water to a hot engine to avoidthe possibility of engine damage. The use ofplain water in the cooling system is not rec-ommended since the aluminium componentsof the cooling system require the use of acorrosion inhibitor found in the recommendedEthylene Glycol type anti freeze solutions.
The engine coolant temperature gauge indicatesthe engine coolant temperature and will, undernormal circumstances, give an indication in the"Normal" or centre portion of the scale. Shouldthe indication move into the upper or "Hot" por-tion of the scale, engine overheating is indicated.Under these circumstances, the vehicle shouldbe brought to rest as soon as is safe to do so andthe engine turned off. Once the engine has cooledsomewhat, the coolant level and the condition ofthe generator/water pump drive belt should bechecked. If the cause of the overheating cannotbe readily established, the assistance of aHyundai dealer should be sought. WARNING: The engine cooling system is pressurizedand removal of the radiator cap when the The tachometer registers the speed of the enginein revolutions per minute (R.P.M.). CAUTION: The maximum safe engine operating speed isindicated by the white zone of the tachometerscale. The engine should not be operatedbeyond the beginning of this zone or seriousengine damage may result.
SB215C1-E SPEEDOMETER
The speedometer indicates the vehicle speed in both miles and kilometres per hour.
HGK132HGK131A
HGK130B

CONTROLS AND EQUIPMENT
1- 46 SB450A2-E HATCHBACK DOOR Remote Hatchback door Release The hatchback door may be opened by pulling the lever to release the lock. The hatchback doorshould be closed by depressing the lid firmly untilthe latch engages. Ensure that hatchback door issecurely latched before setting the vehicle inmotion. WARNING: The hatchback door should always be closedwhilst the vehicle is in motion to preventexhaust gases from being drawn into thepassenger compartment.
HGK103-D
SB440A1-E REMOTE FUEL FILLER LID RELEASE (Not all models) The fuel filler lid may be opened from inside the vehicle by pulling up on the fuel filler lid release. NOTE: If the fuel filler lid will not open because icehas formed around it, tap lightly or push onthe lid to break the ice and release the lid. Donot lever the lid. If necessary, spray aroundthe lid with an approved de-icer fluid (do notuse radiator anti-freeze) or move the vehicleto a warm place and allow the ice to melt.
HGK105-D
HGK124
WARNING: Fuel vapours are dangerous. Before refuel- ling, turn off the engine and never allowsparks, lit cigarettes or open flames near thefiller area. When releasing the filler cap, asmall amount of residual pressure may gen-erate a slight hissing sound which is notindicative of an abnormality. In the event ofthe fuel filler cap requiring replacement, onlya Genuine Hyundai replacement part shouldbe used to prevent fuel leakage.

IN CASE OF EMERGENCY
3-2 4. Check to see if the water pump drive belt is
missing. If it is not missing, check to see that it is tight. If the drive belt seems to be satisfac-tory, check for coolant leaking from the radia-tor, hoses or under the car. (If the air condi-tioning had been in use, it is normal for coldwater to be draining from it).
WARNING:Whilst the engine is running, keep hands andclothing away from moving parts such as thefan and drive belts to prevent injury.
5. If the water pump drive belt is broken or coolant is leaking out, stop the engine imme- diately and call the nearest Hyundai dealerfor assistance.
WARNING:Do not remove the radiator cap when theengine is hot since steam and boiling watermay be ejected from the radiator resulting inburns or scalding.
6. If the cause of the overheating cannot be found, wait until the engine temperature has returned to normal. Then, if coolant has beenlost, carefully remove the radiator cap andadd water to bring the fluid level in the reser-voir up to the base of the radiator fill opening.Fill the coolant expansion tank to the halfwaymark.
WARNING:Motor vehicle batteries contain sulphuric acidand emit hydrogen gas. Protective clothingshould be worn and care exercised to preventthe acid from coming into contact with skin orclothing and the vehicle. Naked lights shouldnot be permitted in the vicinity of the battery.Care should be exercised to prevent sparksoccurring during connection. If acid acciden-tally comes into contact with skin or eyes, theaffected area should immediately be flushedwith copious amounts of water and medicalassistance sought.
1. Ensure that the booster battery is 12 volt type.
If the booster battery is installed in another vehicle, ensure that the two vehicles are nottouching.
2. Turn off all unnecessary electrical equipment in both vehicles.
3. Ensure that the engine of the vehicle provid- ing the jump start is running prior to connec-tion of the jump cables.
4. Connect the red jump cable to the positive (+) terminal of the booster battery and the otherend to the positive (+) terminal of the dis-charged battery.
5. Attach the black jump cable to the negative (-) terminal of the booster battery, and theother end to a ground point within the enginecompartment of the vehicle with the flat bat-tery. Do not connect to the negative batteryterminal of the flat battery since sparks maybe generated with the subsequent risk ofexplosion. 6. Raise the booster vehicle engine speed to
2,000 r.p.m. and start the engine of the vehi-cle with the flat battery.
7. Remove jump cables in the reverse order of installation (black cable first).
CAUTION:If the jump cable is incorrectly installed, dam-age to the vehicle electrical system may oc-cur, in particular the electronic componentssuch as the Fuel Injection system computerand the Automatic Transaxle computer. Thebattery must never be disconnected whilstthe engine is running. SD040A1-E IF THE ENGINE OVERHEATSIf the temperature gauge indicates overheating:
1. Pull off the road and stop as soon as it is safe to do so.
2. Place the gear selector lever in "P" (auto- matic), or neutral (manual transaxle) and set the parking brake. If the air conditioning is on,turn it off.
3. If coolant is running out under the car or steam is coming out from under the bonnetstop the engine. Do not open the bonnet untilthe coolant has stopped running or the steam-ing has stopped. If there is no visible loss ofcoolant and no steam, leave the engine run-ning and check to be sure the engine coolingfan is operating.If the fan is not running, turn the engine off.

VEHICLE MAINTENANCE REQUIREMENTS
5- 6
6ZF070D1-A
o Manual transaxle oil Inspect the manual transaxle oil according to the maintenance schedule. NOTE: If the oil level is low, check for possible leaksbefore adding oil. Do not overfill.
6ZF070H1-A
o Rear brake drums and linings/
parking brake
Check the rear brake drums and linings for scoring, burning, leaking fluid, broken parts, andexcessive wear. Inspect the parking brake sys-tem including the parking brake lever and cables.For detailed service procedures, refer to theShop Manual. 6ZF070J1-A
o Brake pads, calipers and rotorsCheck the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage. 6ZF070K1-A
o Exhaust pipe and mufflerVisually inspect the exhaust pipes, muffler and hangers for cracks, deterioration, or damage.Start the engine and listen carefully for anyexhaust gas leakage. Tighten connections orreplace parts as necessary. 6ZF070L1-A
o Suspension mounting bolts Check the suspension connections for loose- ness or damage. Retighten to the specified torque.
F070E03A-AAT
o Automatic transaxle fluid The fluid level should be in the "HOT" range of the dipstick, after engine and transaxle are at normaloperating temperature. Check the AutomaticTransaxle Fluid level with the engine running andthe transaxle in neutral, with the parking brakeproperly applied. Use DIAMOND ATF SP- III,
SK ATF SP- III when adding or changing fluid. 6ZF070M1-A
o Steering gear box, linkage & boots/
lower arm ball joint
With the vehicle stopped and engine off, check for excessive freeplay in the steering wheel.Check the linkage for bends or damage. Checkthe dust boots and ball joints for deterioration,cracks, or damage. Replace any damaged parts. 6ZF070N1-A
o Power steering pump, belt and hos-
es
Check the power steering pump and hoses for leakage and damage. Replace any damaged orleaking parts immediately. Inspect the powersteering belt for evidence of cuts, cracks, exces-sive wear, oiliness and proper tension. Replaceor adjust it if necessary.
6ZF070F1-A o Brake hoses and linesVisually check for proper installation, chafing, cracks, deterioration and any leakage. Replaceany deteriorated or damaged parts immediately. 6ZF070G2-A
o Brake fluidCheck brake fluid level in the brake fluid reser- voir. The level should be between "MIN" and"MAX" marks on the side of the reservoir. Useonly hydraulic brake fluid conforming to DOT 3 orDOT 4.
6ZF070B1-A
o Cooling systemCheck the cooling system part, such as radiator, coolant reservoir, hoses and connections forleakage and damage. Replace any damagedparts. 6ZF070C1-A
o Coolant The coolant should be changed at the intervals specified in the maintenance schedule.

OWNER MAINTENANCE 6-1
CAUTION: When inspecting or servicing the engine, youshould handle tools and other heavy objectscarefully so that the plastic rocker cover ofthe engine is not damaged.
SG000A1-E
6. OWNER MAINTENANCE
6
G010A01GK-EAT ENGINE COMPARTMENT (1.6 DOHC)
1. Clutch fluid reservoir (Not all models)
2. Engine oil filler cap
3. Brake Booster
4. Brake fluid reservoir
5. Relay box
6. Windscreen washer fluid reservoir cap
7. Power steering fluid reservoir
8. Engine coolant reservoir
9. Engine oil level dipstick
10. Radiator cap11. Automatic transaxle fluid level dipstick
(Not all models)
12. Air cleaner
13. Battery HGK238-D
1
2
345
6 7 8 9 10 11 12 13

OWNER MAINTENANCE
6-2
G010A01GK-EAT ENGINE COMPARTMENT (2.0 DOHC CVVT) HGK059-D
CAUTION: When inspecting or servicing the engine, youshould handle tools and other heavy objectscarefully so that the plastic rocker cover ofthe engine is not damaged.
1. Clutch fluid reservoir (Not all models)
2. Engine oil filler cap
3. Brake Booster
4. Brake fluid reservoir
5. Relay box 6. Windscreen washer fluid reservoir cap
7. Power steering fluid reservoir
8. Engine coolant reservoir
9. Engine oil level dipstick
10. Radiator cap11. Automatic transaxle fluid level dipstick
(Not all models)
12. Air cleaner
13. Battery
1 23
45
6 7 8 9 10 11 12 13

OWNER MAINTENANCE 6-3
G010B01GK-EAT ENGINE COMPARTMENT (2.7 V6) HGK209-D
1. Power steering fluid reservoir
2. Clutch fluid reservoir (Not all models)
3. Brake Booster
4. Brake fluid reservoir
5. Air filter element 6. Relay box
7. Windscreen washer fluid reservoir cap
8. Engine coolant reservoir
9. Engine oil level dipstick
10. Radiator cap11. Engine oil filler cap
12. Automatic transaxle fluid level dipstick
(Not all medels)
13. Battery
1 23 45
7 8 9 10 11 126
13CAUTION: When inspecting or servicing the engine, youshould handle tools and other heavy objectscarefully so that the plastic rocker cover ofthe engine is not damaged.