fuel pump Hyundai Coupe 2003 Owner's Manual

FEATURES OF YOUR HYUNDAI 1- 1
1. FEATURES OF
YOUR HYUNDAI
B010A01GK
B010A02A-GAT FUEL RECOMMENDATIONS Use Unleaded Gasoline Unleaded gasoline with a Pump Octane Rating of 87 (Research Octane Number 91) or highermust be used in Hyundai vehicle. If leaded gaso-line is used, it will cause the catalytic converter tobecome ineffective and the emission controlsystem to malfunction.This can also result in increased maintenanceexpense. To avoid accidental use of leaded fuel,the large nozzle used with leaded gasoline atservice stations can not be inserted into fuel tankopening of Hyundai vehicle. NOTE:
o For some countries, Hyundai vehicles are
designed to use leaded gasoline. Whenyou are going to use leaded gasoline, askto Hyundai dealer whether leaded gaso-line in your vehicle is available or not.
o Octane Rating of leaded gasoline is same with unleaded one.
B010B01A-AAT What About Gasohol? Gasohol (a mixture of 90% unleaded gasoline and 10% ethanol or grain alcohol) may be usedin your Hyundai. However, if your engine devel-ops driveability problems, the use of 100% un-leaded gasoline is recommended. Fuels withunspecified quantities of alcohol, or alcoholsother than ethanol, should not be used. B010D01S-AAT Do not Use Methanol Fuels containing methanol (wood alcohol) should
not be used in your Hyundai. This type of fuel canreduce vehicle performance and damage com-ponents of the fuel system. CAUTION: Your Hyundai's New Vehicle Limited War-ranty may not cover damage to the fuel sys-tem and performance problems that arecaused by the use of methanol or fuels con-taining methanol. B010E01A-AAT Gasolines for Cleaner AirTo help contribute to cleaner air, Hyundai recom- mends that you use gasolines treated with deter-gent additives, which help prevent deposit for-mation in the engine. These gasolines will helpthe engine run cleaner and enhance performanceof the Emission Control System. B010F01A-AAT Operation in Foreign Countries If you are going to drive your Hyundai in another country, be sure to:
o Observe all regulations regarding registra-
tion and insurance.
o Determine that acceptable fuel is available. B020A01S-GAT BREAKING IN YOUR NEW HYUNDAI During the First 2,000 Km (1,200 Miles) No formal "break-in" procedure is required with your new Hyundai. However, you can contributeto the economical operation and durability of yourHyundai by observing the following recommen-dations during the first 2,000 km (1,200 miles).
o Don't drive faster than 88 km/h (55 mph).
o While driving, keep your engine speed (rpm, or revolutions per minute) between 2,000 rpmand 4,000 rpm.
o Use moderate acceleration. Don't start, de- press the accelerator pedal fully.
1

FEATURES OF YOUR HYUNDAI
1- 28
B260J01S-GAT Charging System Warning Light
The charging system warning light should come on when the ignition is turned on, then go outwhen the engine is running. If the light stays onwhile the engine is running, there is a malfunctionin the electrical charging system. If the lightcomes on while you are driving, stop, turn off theengine and check under the hood. First, makecertain the generator drive belt is in place. If it is,check the tension of the belt.And then, have the system checked by yourHyundai dealer. CAUTION: If the drive belt (generator belt) is loose,broken, or mission while the vehicle is driv-ing, there may be a serious malfunction, en-gine could overheat because this belt alsodrives the water pump. B260L01A-GAT
Door Ajar Warning Light
The door ajar warning light warns you that a dooris not completely closed.
B260H01GK-AAT Parking Brake/Low Brake Fluid Level Warning Light
CAUTION: If you suspect brake trouble, have your brakeschecked by a Hyundai dealer as soon aspossible. Driving your car with a problem ineither the brake electrical system or brakehydraulic system is dangerous, and couldresult in a serious injury or death. Warning Light Operation The parking brake/brake fluid level warning light should come on when the parking brake is ap-plied and the ignition switch is turned to "ON" or"START". After the engine is started, the lightshould go out in three seconds.If the parking brake is not applied, the warninglight should come on when the ignition switch isturned to "ON" or "START", then go out in threeseconds. If the light comes on at any other time,you should slow the vehicle and bring it to acomplete stop in a safe location off the roadway.The brake fluid level warning light indicates thatthe brake fluid level in the brake master cylinderis low and hydraulic brake fluid conforming toDOT 3 or DOT 4 specifications should be added.After adding fluid, if no other trouble is found, thecar should be immediately and carefully driven toa Hyundai dealer for inspection. If further troubleis experienced, the vehicle should not be drivenat all but taken to a dealer by a professionaltowing service or some other safe method. Your Hyundai is equipped with dual-diagonalbraking systems. This means you still have brak-ing on two wheels even if one of the dual systemsshould fail. With only one of the dual systemsworking, more than normal pedal travel andgreater pedal pressure are required to stop thecar. Also, the car will not stop in as short adistance with only half of the brake system work-ing. If the brakes fail while you are driving, shift toa lower gear for additional engine braking andstop the car as soon as it is safe to do so.
B260M01A-AAT
Low Fuel Level Warning Light
The low fuel level warning light comes on when the fuel tank is approaching empty. When itcomes on, you should add fuel as soon aspossible. Driving with the fuel level warning lighton or with the fuel level below "E" can cause theengine to misfire and damage the catalytic con-verter.
B260K01F-AAT Tail Gate Open Warning Light
This light remains on unless the tail gate is completely closed.
B265C01O-AAT Traction Control Indicator Lights (If installed)
The traction control indicators change operation according to the ignition switch position andwhether the system is in operation or not.They will illuminate when the ignition key isturned to the "ON" position, but should go outafter three seconds. If the TCS or TCS-OFF

VEHICLE MAINTENANCE REQUIREMENTS
5- 2 1 2 3 4 5 6 7 8 9
10 ENGINE CONTROL SYSTEM MAINTENANCE ENGINE OIL & FILTER (SG OR ABOVE) See Note (1) DRIVE BELT FUEL FILTER (MPI) FUEL LINES, FUEL HOSES & CONNECTIONS TIMING BELT VAPOR HOSE & FUEL FILLER CAP VACUUM CRANKCASE VENTILATION HOSES AIR CLEANER FILTER SPARK PLUGS SPARK PLUGS (PLATINUM COATED) VALVE CLEARENCE (2.0L)
F030A01GK-GAT
SCHEDULED MAINTENANCE The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for all vehi cle services to protect
your warranty. Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.
F030B03GK-GAT R :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.
NO. DESCRIPTION105 84
R
I I 120
96
R I I I I I
R
90 72
R II I
R I I
R R
75 60
R
I I
60 48
R I I I I I I
R
45 36
R I I I
30 24
R I I I I
R
15 12
R
I I
KILOMETERS X 1000 MONTHS
Note : (1) SF OR LOWER: EVERY 10,000 KM OR 6 MONTHS : "R"
FOR 2.0 DOHC CVVT : SH (API), GF-1 (ILSAC) OR ABOVE
(2) FOR EVERY 40,000 KM: "R"
(3) FOR EVERY 96,000 KM OR 48 MONTHS, WHICHEVER OCCURS FIRST : "I"
See Note (2)
1.6 DOHC/2.0 DOHC CVVT (ALT, W/PUMP, P/STR'G) 2.7 V6 (AUTO-TENSIONER, ALT, P/STR'G, A/CON)
See Note (3)

VEHICLE SPECIFICATIONS 9-1
J030A01GK-GAT TIRE
1.6L
MF 60AH 90A
Dual hydraulic with brake booster Ventilated discSolid discCable
9. VEHICLE SPECIFICATIONS
J010A01GK-GAT MEASUREMENT
J060A01F-AAT FUEL SYSTEM
Type Wheel free playRack strokeOil pump type Rack and pinion0 ~ 30 mm (0 ~ 1.18 in.)132 mm (5.20 in.)Vane type
195/65 R15 205/55 R16, 215/45 R17
StandardOption
Overall length Overall widthOverall height (unladen)Wheel base
Front Rear
4395(173)
1760(69.3) 1330(52.4)2530(99.6)1490(58.7)1490(58.7)
Wheel tread mm (in.)
J020A01GK-GAT POWER STEERING
Fuel tank capacity Liter
55 US.gal
14.5 Imp.gal
12
J040A02GK-GAT ELECTRICAL
Item BatteryAlternator
J050A01GK-GAT BRAKE Type Front brake typeRear brake typeParking brake
J035A01GK-GAT SPARE TIRE
T125/70 R16 (Temporary)
Standard
2.0L
MF 68AH 90A2.7L
MF 68AH 95A
9

CONTROLS AND EQUIPMENT1- 1
The use of leaded fuel in this vehicle will result in irreversible pollution of the catalyst element.Such pollution will prevent correct operation ofthe catalyst and give rise to increased operatingtemperatures leading to the catalyst elementmelting and restricting the exhaust flow alongwith an increase in exhaust emission levels. CAUTION: The vehicle warranty will not extend to dam-age arising from the use of incorrect fuels. Overseas Operation: When the vehicle is to be operated overseas, the vehicle operator should establish that a suitablefuel for satisfactory operation of the vehicle isavailable.
B020A01S-EAT RUNNING INThe longevity and performance of the vehicle are greatly affected by the care exercised during thefirst 1,000 miles of motoring. Because of modernmanufacturing techniques, rigid guidelines re-garding maximum road speeds have becomeunnecessary. However, certain precautionsshould be observed in order to obtain the bestpossible performance and useful life from thevehicle.
1) Do not race the engine without a load (i.e
revving the engine in neutral).
2) During the first 500 miles the maximum en- gine speed should be restricted to 3,000 rpmand gradually increased thereafter.
3) Avoid prolonged constant speed operation. The internal components of the engine willbecome more quickly run in if the operationspeed is varied during the running in period.
4) Never allow the engine to labour. Use the gearbox freely and avoid large throttle open-ings when the engine speed is below 1,500rpm.
5) Avoid rapid acceleration and maximum throttle openings.
6) Avoid harsh braking during the first 100 miles of urban motoring or 1,000 miles ofmotorway driving to allow the friction facingsof the brake pads and shoes to bed againstthe discs and drums properly.
7) No trailer towing should be undertaken dur- ing the running in period.
1. CONTROLS AND
EQUIPMENT
B010E01A-EAT PETROLS FOR CLEANER AIR To help contribute to cleaner air, Hyundai recom- mends that you use petrols treated with deter-gent additives, which help to prevent depositformation in the engine. These petrols will helpthe engines run cleaner and the Emission Con-trol System performance.
Unleaded fuel with a Reasearch Octane Number(RON) of 91 or higher must be used in thisvehicle.To prevent accidental charging of the fuel tankwith leaded fuel, a small diameter filler neckalong with a restrictor flap are fitted to ensure thatonly unleaded fuel pump nozzles may enter thefiller neck. However, care must be exercisedwhen refuelling the vehicle tank from jerry cansor by means of a funnel that the fuel being usedis unleaded.
B010A01A-EAT FUEL RECOMMENDATIONS THIS VEHICLE MUST ONLY BE OPERATED WITH UNLEADED FUEL.SERIOUS DAMAGE WILL RESULT FROMTHE USE OF LEADED FUEL.
1
B010A02GK
UNLEADED FUEL ONLY

CONTROLS AND EQUIPMENT
1- 28 SB2100I-E
DOOR AJAR WARNING LAMP
The door ajar warning lamp indicates that a door is not correctly closed. Ensure that the lamp isextinguished prior to driving the vehicle.
SB210P1-E
LOW FUEL LEVEL WARNING LAMP
The low fuel warning lamp serves to warn the driver that the remaining fuel quantity is approxi-mately 9 litres and that the vehicle should berefuelled. If the vehicle is driven for an extendedperiod with the low fuel warning lamp illuminatedthere exists a possibility that misfiring due to fuel
becoming defective, approximately fifty per centof the normal braking performance will be avail-able.If failure of one of the circuits occurs, the requiredamount of pedal effort, pedal travel and stoppingdistance will be increased. Use of the gearbox isrecommended to assist in bringing the vehicle torest. The vehicle must not be driven once brakefailure has occurred until the system has beenrepaired and is functioning normally.The braking system employs a vacuum servo inorder that the pedal efforts are reduced. Powerfor the servo is derived from the engine andtherefore, in the event of the engine stopping orthe vehicle being towed, pedal efforts will besubstantially increased. SB210M1-E
CHARGING SYSTEM WARNING LAMP
The charging system warning lamp should illumi- nate when the ignition switch is turned to the"ON" position and should be extinguished whenthe engine is started. If the lamp fails to illuminatewhen the ignition is turned "ON" or fails to extin-guish after starting the engine, the nearestHyundai dealer should be contacted. If the lampilluminates whilst the vehicle is being driven, stopthe vehicle as soon as it is safe to do so andcheck the condition of the generator drive belt. Ifthe belt is in place and the tension is satisfactory,the advice of a Hyundai dealer should be sought.
B260H01GK-EAT PARKING BRAKE/BRAKE FLUID LEVEL WARNING LAMP
CAUTION: In the event of problems being suspected with the braking system, the advice of thenearest Hyundai dealer must be sought be-fore the vehicle is driven. Driving the vehiclewith either an electrical or hydraulic brakingsystem defect may be dangerous, resultingin accident or personal injury. Warning lamp operation The parking brake/brake fluid level warning lamp will be illuminated whenever the ignition switch isturned to the "ON" or "START" position when theparking brake is applied and must be extin-guished in a three seconds after the enginestarts.If the warning lamp fails to extinguish or illumi-nates at any other time, the vehicle must bebrought to rest in a safe location and the level ofbrake fluid in the reservoir checked. If the fluidlevel is incorrect, fluid conforming to DOT 3 orDOT 4 specifications should be added. If, aftercorrecting the brake fluid level, the warning lampcontinues to be illuminated, the advice of thenearest Hyundai dealer must be sought beforethe vehicle is driven again.The Hyundai Coupe is equipped with a diago-nally split dual braking system which will ensurethat in the event of one of the brake circuits SB210N2-E
HATCHBACK DOOR OPEN WARNING LAMP
The hatchback door warning lamp indicates when the hatchback door is open or is not fully closed.Ensure that the lamp has extinguished prior todriving the vehicle.CAUTION: If the drive belt (generator belt) is loose,broken, or missing while the vehicle is driv-ing, there may be a serious malfunction, en-gine could overheat because this belt alsodrives the water pump.

3-1
IN CASE OF EMERGENCY
the transaxle selector is at the "P" or"N" position.
2. Check the battery terminals and connections to ensure that these are clean and also tight.
3. If the ignition warning lamps dim when the engine is cranked and the battery terminalshave been checked, a discharged battery isindicated.
4. Do not attempt to push or tow start the ve- hicle, refer to "Jump Starting" for informationregarding engine starting when the battery isdischarged.
SD000A1-E
3. IN CASE OF EMER-
GENCY
SD020A1-E IF THE ENGINE WILL NOT STARTSeek assistance from the nearest Hyundai dealer with regard to the method of ignition and fuelsystem diagnosis. WARNING: If the engine refuses to start, no attemptshould be made to push or tow start thevehicle. Vehicles with automatic transaxle orfuel injection will not be able to be started inthis manner since no drive is transmittedthrough the automatic transaxle whilst theengine is not running, and in the case of fuelinjected derivatives, the fuel pump will notoperate under tow start conditions. In addi-tion, if the vehicle is equipped with an ex-haust catalyst, damage to the catalyst mayresult if the vehicle is tow started. SD020B1-E IF THE ENGINE CANNOT BE CRANKED
1. If the vehicle is fitted with manual transaxle, ensure that the clutch pedal is depressedwhilst cranking the engine. If the vehicle isfitted with automatic transaxle, ensure that D010C01A-AAT If Engine Turns Over Normally but Does Not Start
1. Check fuel Level.
2. With the key in the off position, check all
connectors at ignition coils and spark plugs.Reconnect any that may be disconnected orloose.
3. Check the fuel line in the engine room.
4. If engine still refuses to start, call a Hyundai dealer or seek other qualified assistance.
D010D01A-AAT If Engine Stalls While Driving
1. Reduce your speed gradually, keeping a straight line. Move cautionsly off the road to a safe place.
2. Turn on your emergency flashers.
3. Try to start the engine again. If your vehicle will not start, contact a Hyundai dealer orseek other qualified assistance. SD030A1-E JUMP STARTING
3
HGK184
Battery
DOHC
HGK184A
V6
Battery
CAUTION: Personal injury and damage to the vehicle may occur if jump starting is not performedcorrectly. If any doubt exists as to how thisoperation should be performed, seek assis-tance from qualified personnel.

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- 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)

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.