maintenance Hyundai Coupe 2004 Owners Manual

6OWNER MAINTENANCE
26CHECKING THE FREE-PLAY
SG150A1-E STEERING WHEEL Steering wheel freeplay should be checked to ensure that the specifiedvalue is not exceeded. 1.18in. (30 mm)SG160A1-E
CLUTCH PEDAL
The clutch pedal freeplay should be
checked against the specified value. If the freeplay is not correct, the clutch should be adjusted by a Hyundai dealer. 0.24 ~ 0.51 in. (6 ~ 13 mm)
SG170A1-E
BRAKE PEDAL
The brake pedal freeplay should be
checked with the engine turned off. The pedal to floor clearance should be checked with the engine running and a load of 490 N applied to thepedal. If either value is incorrect, the necessary adjustment should be per- formed by a Hyundai dealer. Pedal tofloor clearance: 1.97 in. (50 mm) 0.12 ~ 0.31 in. (3 ~ 8 mm)
HGK5019 G160A01E HXGS508

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OWNER MAINTENANCE
27CHECKING BRAKE PEDAL CLEARANCE
G180A01A-EAT You need a helper to check the brake pedal clearance. With the engine run- ning, have your helper press down onthe brake pedal several times and then hold it down with a force of about 490N (50 kg, 110 lbs). The brakepedal clearance is the distance from the top surface of the brake pedal to the asphalt sheeting under the floormat. If the brake pedal clearance is not within the limits specified in the illustration, have it inspected by yourHyundai dealer and adjusted or re- paired if necessary. 1.78 in.(45.1 mm)
YG190A1-E
CHECKING ENGINE DRIVE BELTS
If a belt is loose, adjust it by:
1. Loosen the adusting bolts justenough so that the components can be moved.
2. Whilst pulling outward on the pry bar or screw driver, test the beltdeflection with your thumb.
3. After tightening the adjusting bolts,
be sure to recheck the belt tension.Overtightening drive belts can cause excessive wear and failure in driven components and belts.
G180A01L
Tension pulleyGenerator
G190A01GK
Power steering
Water pump pulley
A/Ccomp.
2.0L G190A02B
A/C comp.
Crankshaft pulley
Power steering
Auto tensioner
Generator
2.7LWater Pump Pulley
Alternator Pulley
Pulley Crankshaft Pulley 0.2~0.24 in.(5.1~6 mm)
HTB186
1.6L
Crankshaft pulley

6OWNER MAINTENANCE
28
G200A01E
!
FUSIBLE LINKS
SG200A1-E The fusible link prevents damage to the wiring harness in the event of an electrical system malfunction. Failureof a fusiblelink is indicative of a seri- ous overload condition having oc- curred and therefore the electricalsystem should be checked by a Hyundai dealer before a replacement link is fitted. WARNING:
Under no circumstances should a
fusible link be replaced with any-thing other than a new link of thesame rating. The use of higher rated links or other means of con- necting the circuit will create apotential fire hazard.
Melted SG200B2-E
INDIVIDUAL CIRCUIT FUSES
The fuse box containing the individual
circuit fuses is located on the lowerportion of the dashboard adjacent to the bonnet release. The fuse box cover is removed by pushing lightlyand then releasing the lid. A fuse rating grid will be found on the re- verse side of the cover. In the eventof fuse failure, the fuse should be replaced with one of equivalent rat- ing. A fuse removal tool is providedwithin the fuse box to facilitate re- placement.
Good
HGK4003-E

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OWNER MAINTENANCE
29
!
In the event of a replacement fuse failing shortly after installation a mal- function within the circuit protected bythat fuse is indicated. The circuit should be checked by a Hyundai dealer at the first available opportu-nity. WARNING:
The use of replacement fuses hav-ing a higher rating than specified or other means of connecting the circuit will create a potential firehazard. Good
HXDFL1026-1
G200B02L
Burned out
NOTE: See page 6-41 for the fuse panel
descriptions.
!
BATTERY MAINTENANCE
SG210A1-E
WARNING:
Motor vehicle batteries contain sulphuric acid which is corrosiveand poisonous. Hydrogen gas is emitted from the battery which is explosive when combined with oxygen. The following precautions must be strictly observed to avoid personal injury or damage to the vehicle. D010B01GK

6OWNER MAINTENANCE
30
o If battery electrolyte is spilled onto
skin or into eyes, the effected area must be flushed with copious amounts of water and medical assis-tance sought.
o If battery electrolyte is ingested, copious amounts of water or milkfollowed by an ant-acid (raw egg ormilk of magnesia) must be drunk. Vomiting should not be induced and medical assistance must besought.
o Batteries must only be charged in well venti-lated areas from which naked lights or sources of sparks are excluded.
o Ensure that children, pets or other unautho-rized persons are keptaway from batteries.
o Do not allow anything to bridge the
positive (+) and negative (-) termi-nals of the battery.
o Never invert the battery.
The battery fitted during production isof the "Maintenance Free" type.
ELECTRIC COOLING FANS
!
YG210A1-E
WARNING:
The cooling fan is controlled by engine coolant temperature and may sometimes operate even whenthe engine is not running. Do not touch the radiator fan until it is completely stopped.As the coolant temperature de-creases the fan will automaticallyshut off. This is a normal condi- tion.
Checking Engine Cooling Fan The engine cooling fan should auto- matically come on if the engine cool-ant temperature is high.
Checking Condenser Cooling Fan The condenser cooling fan (in front of the condenser) should come on auto- matically whenever the air conditioneris in operation.
POWER STEERING HOSES
YG220A1-E It is suggested that you check the power steering hose connections for fluid leakage at those intervals speci- fied in the vehicle maintenance sched-ule in Section 5. The power steering hoses should be replaced if there are severe surface cracking, pulling, scuff-ing or worn spots. Deterioration of the hoses could cause premature failure. NOTE: The power steering pump may be noisy when the engine is firststarted in the extreme cold (-4°F). This noise is not abnormal and will stop as the engine warms up.If the power steering pump contin- ues to be noisy after the engine has warmed up, have it inspectedby your Authorized Hyundai Dealer.

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OWNER MAINTENANCE
31
HGK5011
G230A03A-EAT
Power Steering Fluid Level Fluid Recommendation
Only automatic transaxle fluid meet-
ing the specification of PSF-3 or ATF DEXRON 2 should be used in thepower steering system.
The power steering fluid level should
be checked regularly.
To check the power steering fluid
level, be sure the ignition is "OFF",then check to make certain that thepower steering fluid level is between the "MAX" and "MIN" level markings on the fluid reservoir.
NOTE: Do not check whilst the engine is
running. Do not start when power steering fluid reservoir is empty.High Beam
G290A01GK
G290A01GK-EAT HEADLIGHT AIMING AD- JUSTMENT
Before performing aiming adjustment, make sure of the following.
G290A02GK
Low Beam
Horizontal aiming Verticalaiming
Horizontal aiming Vertical aiming

6OWNER MAINTENANCE
32
G290B01GK-EAT
Adjustment After Headlight As- sembly Replacement
If the vehicle has had front body
repair and the headlight assembly has been replaced, the headlight aim- ing should be checked using an aim-ing screen as shown in the illustra- tion. Turn on the headlight switch.
1. Adjust headlights so that main axis of light is parallel to centre line of the body and is aligned with point"P" shown in the illustration.
2. Dotted lines in the illustration show centre of headlights. 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 cen- tre : Low Beam: 47.3 in. (1,202mm) High Beam: 38.0 in. (966mm) "L" Distance between the headlights and the wall that the lights are tested against : 118.11 in. (3,000 mm)
1. Keep all tyres inflated to the cor-
rect pressure.
2. Place the vehicle on level ground and press the front bumper & rearbumper down several times. Placevehicle 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, and spare 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 pat- tern) and the horizontal line (through the centre of each headlight beampattern) on the aiming screen.And then, draw a parallel line at1.18 in. (30 mm) under the hori- zontal line.
7. Adjust each cut-off line of the low beam to the parallel line with aphillips screwdriver - VERTICAL AIMING.
8. Adjust each cut-off line of the low beam to the each vertical line witha phillips screwdriver - HORIZON- TAL AIMING. L
G290B01JM-D
W
H
H Cut-off line"P"
Vertical lineHorizontal line
Ground line
1.18 in.

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OWNER MAINTENANCE
33REPLACING LIGHT BULBS
G260A03A-EAT In the event of bulb failure being experienced, ensure that the relative lighting circuit is turned off prior toattempting to replace the bulb. The illustrations on the following page will assist in locating and removing thevarious bulbs. Ensure that the re- placement bulb has the same cap configuration and wattage as the origi-nal.See page 6-40 for the wattage de-scriptions.
CAUTION:
Keep the lamps out of contact withpetroleum product, such as oil, gasoline, etc.
!
HGK5025
G270A01GK-EAT Headlight and Front Turn Signal Light
1. Allow the bulb to cool. Wear eye protection.
2. Open the engine bonnet.
3. Always grasp the bulb by its plastic base, avoid touching the glass.
HGK5024
5. Turn the plastic cover counterclock- wise and remove it.
4. Disconnect the power cord from the bulb base in the back of the headlight. HGK5023
6. Disconnect the connector from thebulb base in the back of the head- light.

6OWNER MAINTENANCE
34
!WARNING:
This halogen bulb contains gas
under pressure and if impacted could shatter, resulting in flying fragments. Always wear eye pro-tection when servicing the bulb. Protect the bulb against abrasions or scratches and against liquidswhen lighted. Turn the bulb on only when installing in a head- light. Replace the headlight if dam-aged or cracked. Keep the bulb out of the reach of children and dispose of the used bulb with care.
11.To replace the front turn signal
light bulb, remove from the bulbholder and install the new bulb. HGK5036
tic base with the headlight hole.Reattach the bulb spring and re-connect the connector.
9. Use the protective cap and carton
to promptly dispose of the old bulb.
10.Check for proper headlight aim.
G270A03O
8. Remove the protective cap fromthe replacement bulb and install the new bulb by matching the plas-
7. Push the bulb spring to remove the
headlight bulb.
HGK5027
HGK5026

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OWNER MAINTENANCE
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G270B01GK-GAT
Rear Combination Light (Without woofer speaker)
1. Open the hatchback door. HGK5037
(1)
(2)
(3)
3. Remove the nut (8mm) with a span-
ner. HGK50424. To detach the rear combination
light hit it strongly by hand. HGK5043
HGK5041
2. To remove the cover of the rear luggage trim, turn the knob by hand to the counterclockwise.