Hyundai Coupe 2003 Owner's Manual

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 runningand a load of 490 N applied to the pedal. If eithervalue is incorrect, the necessary adjustmentshould be performed by a Hyundai dealer. Pedalto 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 beltmust be checked after thirty minutes runningfollowing fitment of the new belt to allow for theinitial 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 indicativeof a serious overload condition having occurredand therefore the electrical system should bechecked by a Hyundai dealer before a replace-ment link is fitted. WARNING: Under no circumstances should a fusible linkbe replaced with anything other than a newlink of the same rating. The use of higherrated links or other means of connecting thecircuit will create a potential fire hazard.G190A01GK
V6
DOHC
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 thedashboard adjacent to the bonnet release. Thefuse box cover is removed by pushing lightly andthen releasing the lid. A fuse rating grid will befound on the reverse side of the cover. In theevent of fuse failure, the fuse should be replacedwith one of equivalent rating. A fuse removal toolis provided within the fuse box to facilitate re-placement.In the event of a replacement fuse failing shortlyafter installation a malfunction within the circuitprotected by that fuse is indicated. The circuitshould be checked by a Hyundai dealer at thefirst available opportunity.
AXA6201B
WARNING: The use of replacement fuses having a higherrating than specified or other means of con-necting the circuit will create a potential firehazard. NOTE: See page 6-22 for the fuse panel descriptions. SG210A1-E BATTERY MAINTENANCE WARNING: Motor vehicle batteries contain sulphuric acid which is corrosive and poisonous. Hydrogengas is emitted from the battery which is ex-plosive when combined with oxygen. Thefollowing precautions must be strictly ob-served to avoid personal injury or damage tothe vehicle.
HGK185-D
SG220A1-E ELECTRIC COOLING FANS WARNING: The cooling fan is controlled by engine cool-ant temperature and may sometimes operateeven when the engine is not running. Useextreme caution when working near the bladesof the cooling fan so that you are not injuredby a rotating fan blade. As the engine coolanttemperature 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 withcopious 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 bedrunk. Vomiting should not be induced andmedical assistance must be sought.
o Batteries must only be charged in well venti- lated areas from which naked lights or sourcesof 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 pumpmay be heard immediately after the engine isstarted in extremely cold condition (below-20°C). In this case, if the noise stops duringwarm up, there is no abnormal function in thesystem. This is due to a power steering fluidcharacteristic in extremely cold conditions. FLUID RECOMMENDATION
Only automatic transaxle fluid meeting the speci-
fication of PSF-3 or Dexron 2 oil 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 surethe ignition is "OFF", then check to make certainthat the power steering fluid level is between the"MAX" and "MIN" level markings on the fluidreservoir.
SG250A2-E REPLACING HEADLIGHT BULBSIn the event of bulb failure being experienced, ensure that the relative lighting circuit is turnedoff prior to attempting to replace the bulb. Theillustrations on the following pharagraph will as-sist in locating and removing the headlight bulbs.Ensure that the replacement bulb has the samecap configuration and wattage as the original.
SG230B1-E POWER STEERING HOSESPower steering hoses should be checked for damage, deterioration and leakage at each ser-vice.
The engine cooling fan should operate before thetemperature gauge reaches the upper portion ofthe scale and the condenser fan should operatewhenever 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 thebulb 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, andspare tyres, jack, and tools).
4. Clean the head lights lens and turn on the headlight.
5. Open the bonnet.
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 a parallel line at 1.18 in. (30mm) under the horizontal line.
WARNING:The halogen bulb contains gas under pres-sure and if impacted could shatter, resultingin flying fragments. Always wear eye protec-tion when servicing the bulb. Protect the bulbagainst abrasions or scratches and againstliquids when lighted. Turn on the bulb onlywhen installed in a headlight. Replace theheadlight if damaged or cracked. Keep thebulb out of the reach of children and disposeof 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 an aimingscreen as shown in the illustration. Turn on theheadlight 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 : LowBeam: 47.3 in. (1,202mm)High Beam: 38.0 in. (966mm) "L" Distance between the headlights and the wallthat the lights are tested against : 118.11 in.(3,000 mm)

OWNER MAINTENANCE 6-21
Wattage
55/55 105
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 spoilerRear Turn Signal Light
Combination Sto p/Tail Light
Back-up Light
License Plate Light Rear Fog Light (Not all models)Wattage
2.4 (LED) 3.5 (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 ABS ABS Blower InjectorO 2 Sensor, ECM
DRLFront fog LightTCM, ECM Horn. A/conditioner Head Light (High)Head Light (LOW)
FUSE RATING
120A50A 30A30A30A30A 30A 30A30A 15A 10A15A 15A 10A15A 15A 15A
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 you inspect the fuse box
on your vehicle, refer to the fuse box label.
Not all models

OWNER MAINTENANCE 6-23
DESCRIPTION
IG COIL
AMP
B/UP LAMP
A/BAG IND A/BAG
HTD MIR
HAZARD
R/WIPER
TAIL-RH
F/WIPER A/C SW
RR DEFOG STOP
TAIL-LH
A/CON ECU
CLUSTER
ROOM LP
P/WINDOW T/GATE IGN
RR FOG
C/LIGHT S/ROOF
S/HTR ABS
AUDIO
G200D01GK-GAT Inner Panel
HGK204-E
PROTECTED COMPONENTS
Ignition Coil, ECM
AMP. Multi Gauge Unit B/Up Lamp Air Bag Indicator Air Bag Outside Mirror Defroster Hazard Warning LightRear Window WiperTaillightFront Window WiperA/ConditionerRear Window Defroster Stop Light Tail lightA/ConditionerECM, Multi Gauge Unit, TCMClusterMap Light, Clock, Audio Power Window Hatchback door OpenA/Con, A.Q.S Sensor Rear Fog C/Lighter, Outside MirrorSunroof Seat Warmer ABS. TCS Audio, Clock
FUSERATING
20A20A 10A 10A 15A10A 10A 15A10A20A10A30A15A 10A 10A10A10A 10A 30A 15A10A 10A 15A15A20A 10A 10A

EMISSION CONTROL SYSTEM 7-1
SH010A1-E EMISSION CONTROL SYSTEMS (Not all models) Depending upon the market for which the vehicleis destined, the emission control system willcomprise one or more of the following emissioncontrol devices. (1) Crankcase emission control system (2) Evaporative emission control system(3) Exhaust emission control system In order that the proper functioning of the emis- sion control systems may be ensured, it isrecommended that the vehicle is inspected andmaintained by an authorized Hyundai dealer inaccordance with the maintenance schedule inthis manual.
SH000A1-E
7. EMISSION
CONTROL SYSTEM
SH010B1-E
1. CRANKCASE EMISSION CONTROL SYSTEM
The positive crankcase ventilation system is employed to prevent air pollution caused byblow-by gases being emitted from the crankcase by introducing fresh air to the crankcase throughthe air cleaner where this mixes with blow-bygases and then passes through the PCV valveinto the intake manifold from where it subse-quently enters the combustion chamber and isburned.
SH010D1-E
3. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is a highlyeffective system which controls exhaust emis-sion while maintaining good vehicle performance.
SH010C1-E
2. EVAPORATIVE EMISSION CONTROL SYSTEM
The Evaporative Emission Control System is designed to prevent fuel vapours from escapinginto the atmosphere through the fuel tank venti-lation system.Whilst the engine is not running, fuel vapours generated inside the fuel tank are absorbed and stored in a charcoal canister. When the engine isstarted, the vapours stored in the canister aredrawn into the induction system through thepurge control solenoid valve and are subse-quently burned.The purge control solenoid valve is controlled bythe ECU; when the engine coolant temperatureis low or the engine is idling, the purge controlvalve is closed and fuel vapours remain stored inthe canister. Under normal running conditionswhen the engine is warm, the valve opens andthe vapours are drawn into the inlet tract andsubsequently burned in the combustion cham-ber. SH020A1-E CATALYTIC CONVERTOR OPERATING PRECAUTIONS Hyundai Coupe models are fitted with catalytic convertors which require special operating con-siderations. The catalytic convertor serves tooxidize certain noxious elements of the exhaustgases leaving the engine to reduce the level ofpollutants emitted from the vehicle and, providedthat care is exercised to prevent damage, thecatalyst will operate efficiently for the life of thevehicle.It is of the utmost importance that the followinginformation is read and understood by the ve-
7
Catalytic Converter
SSA7020A

EMISSION CONTROL SYSTEM
7-2
hicle operator in order to prevent operational problems arising from damage to the catalyst.Damage to the catalyst will result if contamina-tion occurs through the use of leaded fuel. Whilstthe vehicle is fitted with a reduced diameter fillerneck to prevent charging of the fuel tank with aleaded fuel pump nozzle, it is possible that theuse of funnels or jerry cans will permit leaded fuelto be introduced into the fuel tank.The catalyst is intolerant of unburnt fuel andtherefore if an engine misfire condition exists,damage to the catalyst will occur. It is imperativethat if a misfire condition develops, the vehicle isimmediately presented to a Hyundai dealer forrectification. Similarly, the practice of certainignition system diagnosis procedures which in-volve inducing a misfire (cylinder power balancetests for example) may result in catalyst dam-age.For these reasons, it is advisable that the ex-haust gas emission be tested at each routineservice with a gas analyzer having a Hydrocar-bon measuring facility to ensure continued reli-ability of the catalyst.Push or tow starting of the vehicle is to beavoided since unburnt fuel may be enter thecatalyst and result in damage. (Note, it is impos-sible to push or tow start a Hyundai modelequipped with fuel injection since the fuel pumpsafety interlock will prevent the pump from oper-ating under these conditions).Operation of the catalyst involves extremely hightemperatures being attained within the catalyticconvertor, and although the convertor is fitted
with heat shields, it is important that the vehicleis not parked over combustible or volatile mate-rial which may result in fire.If the above precautions are not adhered to andthe catalyst becomes inoperative, the resultantincrease in core temperature will result in a "meltdown" where the catalyst core will melt andsubsequently may block the exhaust system.Due to the fragile nature of the catalyst element,it is important that damage does not occur whenthe vehicle is raised by means of a garage jack.Care must also be exercised to avoid drivingover road hazards or debris which may causedamage to the catalyst element.