maintenance Hyundai Coupe 2003 Manual PDF

OWNER MAINTENANCE
6-10 15 seconds continuously or when the reser- voir is empty since damage to the washerpump will result. SG100A1-E MANUAL TRANSAXLE LUBRICANT The manual transaxle lubricant must be checkedand/or changed at the intervals specified in themaintenance schedule. Only those lubricantsspecified should be used in order to prevent gearshifting difficulties or transaxle damage. WARNING: The transaxle lubricant level should only bechecked when the engine is cold to precludethe possibility of personal injury by contactwith hot components. Recommended Oil
SG080A2-E WINDSCREEN WIPER BLADES
SG090A1-EWINDSCREEN WASHER RESERVOIRREPLENISHMENT
The wiper blades should be carefully inspected from time to time and cleaned to remove accu-mulations of road film or other debris. To cleanthe wiper blades and arms, use a clean spongeor cloth with a mild soap or detergent and water.If the wipers continue to streak or smear theglass, replace them with genuine Hyundai re-placement. CAUTION:
o Do not operate the wipers on dry glass since rapid wear and damage to thewindscreen glass may result.
o Keep the blade rubber out of contact with petroleum products such as engine oil,petrol etc. The level of windscreen washer fluid availableshould be checked on a daily basis. The level offluid will be visible through the side of the reser-voir. When the fluid is to be replenished, only aproprietary screen wash additive should be usedand in the concentration recommended by themanufacturer. The windscreen washer reservoirhas a total capacity of 3 litres. CAUTION: Engine coolant anti freeze must not be usedin the windscreen washer system since dam-age to the paintwork may result.Undiluted windscreen washer additive mustnot be allowed to come into contact with thepaintwork. If spillage occurs, flush the af-fected area immediately with water. Do notoperate the windscreen washer for more than
HGK217
HEF119
To ensure maximum filtration performance and continued engine performance, only genuineHyundai replacements should be used.
G110A01E
Filler plug
Drain plug

OWNER MAINTENANCE 6-11
Ensure that the vehicle is parked on level ground with the parking brake firmly applied and theengine cool. Remove the level plug from thetransaxle when lubricant should begin to dripfrom the level hole. If the level is low and nolubricant is seen to drip, add the required quantityof lubricant and replace the plug. scribed in the maintenance schedule. It is ofparamount importance that only the specifiedfluid is used when replenishing or changing thefluid. The use of other fluids may irreparablydamage the transaxle and invalidate the manu-facturers warranty. In addition the ingress of dirtor lint may prevent correct functioning of thetransaxle and care must be exercised to preventthe ingress of such matter. NOTE: Basically automatic transaxle fluid is red color.As driving distance increases, the fluid colorturns darkish red gradually. It is normal con-dition and you should not use fluid color as acriterion for replacing the transaxle fluid.You must replace the automatic transaxlefluid in accordance with intervals specified inthe vehicle maintenances schedule in sec-tion 5. CAUTION: The transaxle fluid level must be checkedwith the engine running and at normal oper-ating temperature and therefore care must beexercised to prevent injury occurring throughcontact with rotating or hot parts of the en-gine. G110B03A-AAT Recommended FluidYour Hyundai automatic transaxle is specially designed to operate with DIAMOND ATF SP-
III,
SK ATF SP- III.
Damage caused by a nonspecified fluid is notcovered by your new vehicle limited warranty. G110D02GK-EAT Transaxle fluid level checking The vehicle must be parked on level ground with the parking brake firmly applied and the engine atnormal operating temperature. (Normal operat-ing temperature will only be achieved when thevehicle has been driven for 6 miles or more).With the engine idling and the footbrake applied,the transaxle selector should be moved from the"P" position through to the "L" position and backto the "N" or "P" position.Open the bonnet and remove the transaxle dip-stick, remembering that care must be exercisedto prevent injury occurring through contact withhot or rotating parts of the engine.Wipe the dipstick, replace it fully and promptlyremove it again. The fluid level should be be-tween the upper and lower marks. Fluid needonly be added if the level is at or below the lowermark and must never be increased above the
DOHC V6
HGK212
Use only the approved transaxle lubricant. The recommended lubricants are complete in them-selves and the use of additives is neither re-quired nor recommended. The use of additivesmay invalidate the vehicle warranty. Transaxle Lubricant Level Checking SG110A2-E AUTOMATIC TRANSAXLE FLUID The automatic transaxle fluid level should bechecked and changed at those intervals pre-
SSA6100B

OWNER MAINTENANCE
6-12 SG120A1-E BRAKE SYSTEM CHECKING CAUTION: Correct operation of the braking system is essential to the safe operation of the vehicleand therefore, any maintenance operationsother than those listed below should be en-trusted to a Hyundai dealer. SG120C2-E Brake Fluid Recommendations Only brake fluid conforming to DOT 3 or DOT 4 specifications or higher may be used in thebraking system. Care should be taken to ob-serve the instructions and precautions printedupon the container. SG120D1-E Brake Fluid LevelThe fluid level in the brake fluid reservoir should be checked periodically. The level should bebetween the "MIN" and "MAX" marks on the sideof the reservoir. If the level is at or below the"MIN" mark, fluid should be added having care-fully cleaned the area surrounding the reservoircap to ensure that dirt is not allowed to enter thesystem. It should be borne in mind that the brakefluid level will decrease slightly as the frictionlinings of the pads and shoes become worn andthat this is a normal condition.
higher mark. If additional fluid is required, thisshould be poured into the transaxle through thedipstick tube with the aid of a suitable funnel. 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.
CAUTION:The automatic transaxle unit is a precisionengineered assembly and correct operationis dependant upon the exclusion of dirt andlint from the unit. Therefore, it is imperativethat only lint free cloth (eg nylon) is used forwiping the dipstick and that the area aroundthe dipstick is thoroughly clean prior to levelchecking or adding fluid. Fluid Capacity The total fluid capacity of the transaxle unit is 7.8 litres.
HGK174-D
Fluid level should be within this range
HGK249
ÎÎ

OWNER MAINTENANCE 6-13
WARNING: Brake fluid is hygroscopic and should neverbe stored in an unsealed container. The pres-ence of water in the braking system will causevapour locks and increase the possibility ofbrake fade along with promoting corrosionwithin the braking system. The brake fluidmust be changed at the specified time ormileage interval to ensure continued safeoperation of the system. Brake fluid will causerapid and serious damage to paintwork. Ifaccidental spillage occurs, the affected areamust be rinsed with water immediately. Donot allow brake fluid to come into contactwith the eyes or to be ingested and ensurethat fluid is safely stored away form the reachof 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 bonnetchecks. 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 onthe fluid reservoir. Fill as required. Fluid lossindicates a leak in the clutch system whichshould be inspected and repaired immediately.
SG130B2-E Adding FluidRecommended brake fluid conforming to DOT 3 or DOT 4 should be used. The reservoir cap mustbe fully tightened to avoid contamination fromforeign matter or moisture. CAUTION: Brake fluid is hygroscopic and should neverbe stored in an unsealed container. Do notallow petroleum base fluid to contaminatethe brake fluid since damage to the rubberseals 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 withwater immediately. Do not allow brake fluidto come into contact with the eyes or to beingested and ensure that fluid is safely storedaway form the reach of children. SG140A1-E AIR CONDITIONING SYSTEMMAINTENANCE Condenser Ensure that the condenser is periodically in- spected and that accumulations of dirt, deadinsects and leaves etc, are removed to ensurethat 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 about0.3 inches (8 mm) when a force of 98 N is appliedto the belt halfway between the compressor andcrankshaft pulleys. Adjustment of the belt shouldbe entrusted to a Hyundai dealer.
SG140C2-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. If the air coming out of the in-dash vents is not cold, have the air conditioning system in-spected by your Hyundai dealer.
CAUTION:Running the air conditioning system for ex-tended periods of time with a low refrigerantlevel may damage the compressor. A/C
CRANK PULLEY
TENSION PULLEY 0.315 in. (8mm)
G140D01GK
V6
DOHC
Auto tensioner
Eng.pulley COMP
SG140D1-E Off Season Maintenance The air conditioning must be run for ten minutes or so weekly during periods when the systemwould not normally be used to ensure that thecompressor and seals are lubricated. If this pre-caution is not observed the compressor sealsmay become stuck to the compressor shaft anddamaged when the system is next used resultingin a loss of refrigerant and damage to the com-pressor. B760B01GK-GAT Replacement of air conditioner filter:
HGK250-D
1. Remove the mounting screws on the down- side of the glove box.
2. Open the glove box and remove the mounting screws on the upside of the glove box.
HGK251-D

OWNER MAINTENANCE 6-15
4. Replace the air filter with a new one.
5. Installation is the reverse order of disassem-bly. CAUTION:Be sure to install the air filter in the directionof the arrow sign. Otherwise, it may causenoise or deterioration. 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 notcorrect, the clutch should be adjusted by aHyundai dealer.
1.18in.(30 mm)
3. Remove the filter cover.
HGK253-D
HGK254-D

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.