maintenance Hyundai Coupe 2003 Workshop Manual

DRIVING YOUR HYUNDAI
2- 4 SC060B1-E FUEL ECONOMY
The following suggestions are made to assist in
achieving the greatest degree of fuel economy.
o Maintaining a constant check on fuel con- sumption will enable the most economical use pattern and driving style to be adopted.
o Avoid using the vehicle for very short jour- neys if possible, particularly when a coldstart is involved.
o Ensure that tyre pressures are maintained at the correct level.
o Use only the recommended grade of fuel.
o Avoid carrying unnecessary weight, and if a roof rack is in use, remove it as soon as possible after use.
o Anticipate the road and conditions ahead to enable adjustments in speed to be madesmoothly. Avoid heavy acceleration and sharpbraking.
o Avoid cruising at unnecessary high speeds.
o Always ensure that the periodic maintenance services are performed by a Hyundai dealer
at the time and/or mileage intervals speci-fied.
o Use the air conditioning only when neces- sary.
NOTE: Do not operate the starter for more than 15
seconds continuously or continue to oper- ate the starter after the engine has started toavoid damaging the starter motor. If theengine makes a false start, allow it and thestarter motor to come to rest before at-tempting to start the engine again. Neverattempt to start the engine with the transaxlein gear. Do not depress the accelerator pedalwhilst starting the engine. Allow the engineto idle for 20 seconds or so before drivingthe vehicle.
CAUTION: Do not leave the vehicle unattended whilst
idling. Never allow the vehicle to idle or warm up in a confined space (ie garage)longer than is necessary to move the vehi-cle into an open area. C070A01GK-EAT MANUAL TRANSAXLE The five speed fully synchronized transaxle is controlled by a floor mounted shift lever uponwhich the shift pattern is indicated. It is importantthat when changing gear, the clutch pedal is fullydepressed to avoid transaxle damage.
HGK242
Mis-shift preventiontab
HGK181
A Type B Type
B Type

DRIVING YOUR HYUNDAI 2- 11
heat, which reduces their effectiveness and may lead to more serious consequences.
o Take care of your tires. Keep them inflated to the recommended pressure. Incorrect infla-tion, either too much or too little, results inunnecessary tire wear. Check the tire pres-sures at least once a month.
o Be sure that the wheels are aligned cor- rectly. Improper alignment can result fromhitting curbs or driving too fast over irregularsurfaces. Poor alignment causes faster tirewear and may also result in other problemsas well as greater fuel consumption.
o Keep your car in good condition. For better fuel economy and reduced maintenancecosts, maintain your car in accordance withthe maintenance schedule in Section 5. Ifyou drive your car in severe conditions,more frequent maintenance is required (seeSection 5 for details).
o Keep your car clean. For maximum service, your car should be kept clean and free ofcorrosive materials. It is especially impor-tant that mud, dirt, ice, etc. not be allowed toaccumulate on the underside of the car. Thisextra weight can result in increased fuelconsumption and also contribute to corro-sion.
o Travel lightly. Don't carry unnecessary weight in your car. Weight is an enemy of good fueleconomy.
o Don't let the engine idle longer than neces- sary. If you are waiting (and not in traffic),turn off your engine and restart only whenyou're ready to go. o Remember, your car does not require ex-
tended warm-up. As soon as the engine isrunning smoothly, you can drive away. Invery cold weather, however, give your en-gine a slightly longer warm-up period.
o Don't "lug" or "over-rev" the engine. Lugging is driving too slowly in too high a gearresulting in the engine bucking. If this hap-pens to you, shift to a lower gear. Over-revving is racing the engine beyond its safe limit. This can be avoided by shifting atthe recommended speeds.
o Use your air conditioning sparingly. The air conditioning system is operated by the en-gine power so your fuel economy is reducedwhen you use it.
SC160A1-F
SMOOTH CORNERING
Avoid braking or gear changing in corners,
especially when roads are wet. Ideally, cornersshould always be taken under gentle accelera-tion. If you follow these suggestions, tire wearwill be held to a minimum.
SC170A1-E
WINTER MOTORING The onset of winter conditions subject motor
vehicles to greater operating demands. There-fore, the following suggestions will assist inmaintaining peak performance and reliabilityduring these periods: ZC170B1-E
Electrical System
Winter conditions impose severe demands uponvehicle electrical systems, particularly the charg-ing circuit. The battery condition and perfor-mance along with the alternator performanceand drive belt condition should be checked priorto the onset of winter. ZC170C1-E
Anti-freeze/Corrosion inhibitor The cooling system must always contain an Ethylene-Glycol based anti-freeze solution. Thesystem is filled during manufacture with solu-tion of the correct strength which should bechecked before the onset of winter and adjust- ed or changed as required. NOTE: The anti-freeze solution contains a corro- sion inhibitor to prevent degradation of thealuminum castings contained within theengine. Therefore, never, drain the systemand refill with water only. In addition, anti-freeze solution must ALWAYS be used in vehicles fitted with air conditioning,to prevent the heater matrix from freezing andsubsequently bursting with the refrigeration sys-tem in use.

APPEARANCE CARE 4-1
retreatment programme must be observed in accordance with the Terms and Conditionsoutlined in the separate Anti Perforation War-ranty Booklet.
NOTE: The underbody should never be steam
cleaned since the underbody coating may be removed by this process.
During the interim period between power
washing the underbody, the more vulnera-ble areas such as wheel arches should behosed off particularly during the winter sea-son to prevent prolonged contact with roadsalts. Ensure that the various drain points located
at the bottom of the door panels and sillsare kept clear to prevent water from becom-ing trapped within the cavities. Whereverpossible, the parking of the vehicle in aconfined, poorly ventilated location (a ga-rage for example) should be avoided whenthe vehicle is wet or is covered with snow orice. Under these conditions, the internalcavities of the vehicle will remain damp forprolonged periods of time which will en-courage corrosion. Parking the vehicle wheregood ventilation exists (outside for example)is preferable.
SE020A1-E PROTECTING YOUR HYUNDAI FROM CORROSION By using the most advanced design and con- struction practices, every Hyundai is built toretain the original factory finish for many years.However, long term durability is also greatlydependant upon maintaining the various protec-tion systems and coatings used in manufacturesince constant, exposure to the elements willresult in a breakdown and loss of effectiveness.The following suggestions are made to assist inthe maintenance of the vehicle bodywork.
SE030A1-E UNDERBODY COATINGS Every Hyundai passenger car receives a full
underbody and cavity injection treatment during production. In order that this treatment mayretain maximum effectiveness it is recommend-ed that the underbody receives a power washand a thorough inspection after each winterseason. In doing so any accumulations of mud,which act as moisture traps and combine withroad salts to accelerate corrosion will be re-moved. In order to maintain the Anti PerforationWarranty, the requirements regarding the
SE000A1-E
4. APPEARANCE
CARE
E030A01GK-AAT VALETINGRegular cleaning of the exterior paintwork serves two important functions. Firstly, the removal of abrasive dirt and contaminants will maintain thelustre of the paintwork and will preventdiscolouration and dulling due to prolonged con-tact.Secondly, the presence of damage through im-pact or abrasion will be apparent allowing earlyrectification to be made thus preventing corro-sion from becoming established and spreadingbeneath the paint film. To avoid "water spotting"the vehicle should not be washed in direct sun-light particularly in the case of vehicles havingdark body colours. The heat from the sun rays isabsorbed by the paint film increasing the surfacetemperature. This action causes water used forwashing to evaporate quickly leaving behind thedeposits from the water and the shampoo used.Use only a shampoo intended for the purposeand ensure that the body work is thoroughlywetted to soften the dirt film prior to attempting toremove this.After removing the dirt film with a soft sponge, thebody work should be thoroughly rinsed and thendried with a good quality chamois leather toprevent streaking or spotting of the paint work.Household detergents, solvents and abrasivecleaning materials should not be used in order toavoid damaging the paint film.High pressure car washes may cause water toenter your vehicle.Plastic wheel covers should be cleaned using asponge and water. Cast alloy wheels should becleaned using a mild soap or neutral detergent.Abrasive compounds must not be used since inthe event of these damaging the lacquer coating,
4

APPEARANCE CARE
4-2
oxidization of the aluminium wheel will occur, spoiling the appearance.The use of an a toothbrush will facilitate cleaningbetween the wheel "spokes". SE040B1-E STAIN/SPOT REMOVAL Should tree sap, dead insects or tar prove to be difficult to remove from the paint film, turpentineor a proprietary paint cutting compound may beused. Ensure that the area to be cleaned is notrubbed intensively to prevent breaking throughthe colour coat and exposing the under coat. SE040C1-E POLISHING The exterior paint work should be polished with a proprietary wax polish when water no longercollects in bead form on the paint work. Theinstructions of the product manufacturer shouldbe adhered to. SE040E1-E BUMPER MAINTENANCEThe special material from which the bumpers are manufactured warrants special attention to pre-serve the appearance of the bumpers. Avoidcontact with battery electrolyte or brake fluid andensure that accidental spillages are immediatelyflushed with water.Do not use abrasive cleaning materials whichmay damage the bumpers.
SE040F1-E ACCIDENT REPAIRSIn the event of the body work sustaining damage, the following points should be noted prior torepairs being undertaken.If body panels are replaced or repaired, anticorrosion treatment must be applied to the repairarea. The product used must be compatible withthose used in manufacture. It is recommendedthat repairs are entrusted to a Hyundai dealer toensure that replacement parts used are of thesame high quality as those used in manufactureof the vehicle and that the correct repair methodsand materials will ensure adequate levels ofcorrosion protection and the continued validity ofthe Anti Perforation Warranty. SE050A1-E INTERIOR During the winter period, it is possible that the passenger compartment flooring may becomewet from damp footwear or quantities of snowadhering to footwear. The carpet should not beallowed to remain in this condition since thecarpet may begin to create musty smells and willpromote corrosion of the floor pan in addition tothe carpet and under felt beginning to rot. SE050C1-E INTERIOR VALETINGThe soft trim and carpets should be maintained with the regular use of a vacuum cleaner. Heavysoiling should be removed with a dry cleaningagent recommended for this purpose followingthe instructions of the product manufacturer.Paint thinner, solvents or other such cleaningmaterials should not be used since damage tothe upholstery may result.
SE050D1-E SEAT BELTSSeat belts should be cleaned only with a mild soap solution. Strong detergents, solvens orbleaches may damage the belt webbing andtherefore reduce the effectiveness of the belt.Belts which display signs of fraying, wear of cutshould be replaced. SE050E1-E WINDOWSA proprietary glass cleaner should be used to clean the inside of the windows. However, therear heated windscreen must only be cleanedusing a light horizontal cleaning action. Careshould be exercised to avoid the use of abrasivecleaners or contact with items of jewellery whichmay damage the heating elements.
Avoid subjecting the bumpers to high tempera-tures such as may be encountered in high bakepaint ovens.

VEHICLE MAINTENANCE REQUIREMENTS 5-1
SF020A1-E MAINTENANCE AND SERVICINGREQUIREMENTS To ensure the continued reliability and safety ofthe vehicle, certain routine maintenance opera-tions are required at specific mileage or timeintervals.It is the responsibility of the vehicle owner toensure that the maintenance schedules shownin both this Owners Manual and the Warrantyand Service Passport are adhered to.The new vehicle warranty may be invalidated ifthe routine maintenance operations are not per-formed in line with the recommendations outlinedand the safety and durability of the vehicle ad-versely affected.It is recommended that all maintenance opera-tions with the exception of the daily operatingchecks are entrusted to a Hyundai dealer toensure that the latest repair and maintenanceprocedures and specialized servicing tools areemployed. In addition, the use of genuine Hyundaireplacement parts will ensure that the vehiclesafety and performance will not be compro-mised.
SF000A1-E
5. VEHICLE MAINTE-
NANCE REQUIRE- MENTS NOTE: The inspection and testing of certain elec-tronic fuel injection/engine management andautomatic transmission control systems re-quire specialised electronic equipment spe-cifically designed for Hyundai vehicles. Theuse of general purpose electrical test equip-ment may result in damage to the control unitmicroprocessors. SF020C1-E Specified Scheduled Procedures
The Specified scheduled procedures are listed
in the maintenance charts beginning at page 5- 2. The operations specified must be performedat the time or mileage intervals shown irrespec-tive of whether the mileage interval has beenreached before the specified time interval.
Certain lubricants and components degrade
with both time and mileage (e.g. engine oil andbrake fluid) and therefore it is not permissableto base the maintenance schedule upon mile-age alone. It is strongly recommended that themaintenance operations are performed by thefactory-trained or distributor-trained techniciansat your Hyundai dealer because of the need forspecialized knowledge and tooling and to en-sure that no possibility of invalidating the man-ufacturers warranty exists.
The maintenance schedules relate to vehicles
operated under normal conditions, vehicles which are operated under adverse conditionswill require more frequent maintenance which isdescribed at page 5-4. SF030B1-E SERVICE HISTORY It is important that all scheduled maintenance services are recorded in the warranty and ser-vice passport to ensure that proof of mainte-nance is available when warranty service isrequired.
5

VEHICLE MAINTENANCE REQUIREMENTS
5- 2
SF040A3-E SCHEDULED MAINTENANCEIn order to ensure the continued safety, reliability and longevity of the vehicle, the following maintenance service operations should be performed at the timeor mileage intervals specified.It is recommended that all routine maintenance services are entrusted to a
Hyundai dealer to ensure that the manufacturers recommended proceduresare employed and that only genuine Hyundai replacement parts are used.Incorrect maintenance techniques or the use of non genuine replacement partsmay invalidate the vehicle warranty.
F030B01GK-EAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
ENGINE CONTROL SYSTEM MAINTENANCE
ENGINE OIL & FILTER(SG OR ABOVE) See Note (1)
DRIVE BELT 2.0 DOHC CVVT (ALT, W/PUMP, P/STR'G) 1.6 DOHC / 2.7 V6 (AUTO-TENSIONER, ALT, P/STR'G, A/CON)
FUEL FILTER(MPI TYPE)FLUID LEAKS TIMING BELTVENTILATION HOSE AIR CLEANER FILTER SPARK PLUG(1.6/2.0L)SPARK PLUGS(2.7L) VALVE CLEARENCE (2.0 DOHC CVVT)
NO. DESCRIPTION60 72
R I I I
RR R R
5060
R
I I I
4048
R I
R I
R R
30 36
R I I I I
20 24
R I I
R R
10 12
R
I I
MILES X 1000 MONTHS
Note :
(1) SF OR LOWER: EVERY 6,000 MILES OR 6 MONTHS: "R"
FOR 2.0 L DOHC VVT : SH (API), GF-1 (ILSAC) ABOVE
(2) FOR EVERY 60,000 MILES OR 48 MONTHS, WHICHEVER OCCURS FIRST : "I"
1 2 3 4 56 7 8 9
See Note (2)

VEHICLE MAINTENANCE REQUIREMENTS 5-3
I I I I II I I I I
R
III I II I I
F030C02GK-EAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
GENERAL MAINTENANCE COOLING SYSTEM COOLANT COOLANT SPECIFIC GRAVITYMANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID BRAKE PIPES, HOSES, AND CONNECTIONSBRAKE FLUID CLUTCH FLUID REAR BRAKE LININGS AND CYLINDERSBRAKE PADS SUSPENSION AND STEERING SYSTEM FRONT SUSPENSION BALL JOINTSPOLLEN FILTER (For Blower unit) REAR WHEEL BEARINGS TYRE CONDITION AND PRESSURE (incl. Spare)LUBRICATE LOCKS AND HINGES CHECK ALL ELECTRICAL SYSTEMS ROAD TESTCHECK ALL SYSTEMS WITH HI-SCAN CHECK 4 GAS DRIVE SHAFT & BOOT
MILES X 1000 MONTHS
NO. DESCRIPTION1 2 34 5 67 8 9
10 11 1213 14 1516 17 1819 20 21I I I I II I I I I
R
III I II I I
10 12 202430364048 50606072
I
R I I I I
R R I I I I
R
III I II I II
R I I I I
R R I I I I
R
III I II I I I I I I II I I I I
R
III I II I I I
R II
R I
R R I I I I
R
III I II I I

VEHICLE MAINTENANCE REQUIREMENTS
5- 4 MAINTENANCE UNDER SEVERE USAGE CONDITIONS
The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals. R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
F040A02GK-EAT
DRIVING
CONDITION
R R RR
I I II
R RR
MAINTENANCE ITEM MAINTENANCE
OPERATION MAINTENANCE
INTERVALS
ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGSTIMING BELTBRAKE PADS, CALIPERS AND ROTORSREAR BRAKE DRUMS/LININGS, PARKING BRAKESTEERING GEAR BOX, LINKAGE & BOOTS/LOWER ARM BALL JOINTDRIVESHAFTS & BOOTSMANUAL TRANSAXLE OILAUTOMATIC TRANSAXLE FLUIDPOLLEN FILTER(FOR BLOWER UNIT) EVERY 4,500MILES OR 6 MONTHSEVERY 3,000MILES OR 6 MONTHSMORE FREQUENTLYMORE FREQUENTLYEVERY 37,000MILES OR 48MONTHSMORE FREQUENTLYMORE FREQUENTLY MORE FREQUENTLYEVERY 9,000MILES OR 12 MONTHS EVERY 60,000MILESEVERY 27,000MILESMORE FREQUENTLY
A, B, C, F, H C, E B, HD, E, F, GC, D, G, HC, D, G, H C,D,E,FC, D, E, F, G A, C, D, E, F, G, H, I, JA, C, E, F, G, H, IC, E
SEVERE DRIVING CONDITIONS
A - Repeated short distance driving
B - Extensive idling
C - Driving in dusty, rough roads
D - Driving in areas using salt or other corrosive materials or in very cold weather
E - Driving in sandy areas F - More than 50% driving in heavy city traffic during hot weather
above 90°F (32°C)
G - Driving in mountainous areas
H - Towing a trailer
I - Driving as a rental car, taxi, other commercial use or vehicle towing
J - Continuous driving over 100 MPH
1.6 DOHC / 2.7 V6 2.0 DOHC CVVT

VEHICLE MAINTENANCE REQUIREMENTS 5-5
6ZF060D1-A
o Fuel lines, fuel hoses and connec-
tions
Check the fuel lines, fuel hoses and connections for leakage and damage. Replace any damagedor leaking parts immediately. 6ZF060E1-A o Timing beltInspect all parts related to the timing belt for damage and deformation. Replace any dam-aged parts immediately. 6ZF060G1-A
o Vapour hose and fuel filler cap The vapor hose and fuel filler cap should be inspected at those intervals specified in the main-tenance schedule. Make sure that a new vapourhose or fuel filler cap is correctly replaced. 6ZF060F1-A
o Vacuum, crankcase
ventilation hoses
Inspect the surface of hoses for evidence of heat and/or mechanical damage. Hard and brittle rub-ber, cracking, tears, cuts, abrasions, and exces-sive swelling indicate deterioration. Particularattention should be paid to examining those hosesurfaces nearest to high heat sources, such asthe exhaust manifold.Inspect the hose routing to assure that the hoses do not come in contact with any heat source,sharp edges or moving component which mightcause heat damage or mechanical wear. Inspectall hose connections, such as clamps and cou-plings, to make sure they are secure, and that noleaks are present. Hoses should be replacedimmediately if there is any evidence of deteriora-tion or damage. 6ZF060H1-A
o Air cleaner filterA Genuine Hyundai air cleaner filter is recom- mended when the filter is replaced. 6ZF060J1-A
o Spark plugs Make sure to install new spark plugs of the correct heat range.
6ZF060A1-A EXPLANATION OF SCHEDULED MAINTENANCE ITEMS 6ZF060M1-A
o Engine oil and filterThe engine oil and filter should be changed at the intervals specified in the maintenance schedule.If the car is being driven in severe conditions,more frequent oil and filter changes are required. 6ZF060B2-A
o Drive belts Inspect all drive belts for evidence of cuts, cracks, excessive wear or oil saturation and replace ifnecessary. Drive belts should be checked peri-odically for proper tension and adjusted as nec-essary. 6ZF060C1-A
o Fuel filterA clogged filter can limit the speed at which the vehicle may be driven, damage the emissionsystem and cause hard starting. If an excessiveamount of foreign matter accumulates in the fueltank, the filter may require replacement morefrequently.After installing a new filter, run the engine forseveral minutes, and check for leaks at theconnections.
F060N02E-EAT
o Valve Clearance Inspect excessive valve noise and/or engine vibration and adjust if necessary. A qualifiedtechnician should perform the operation.

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.