light Hyundai Coupe 2004 Service Manual

WHAT TO DO IN AN EMERGENCY 3-5
4. Reinstall the wheel cap by fitting the boss of
the wheel cap in the groove of the wheel, hitting the center of the wheel cap with yourhand. D060D02A-AAT 3. Loosen Wheel Nuts The wheel nuts should be loosened slightly be- fore raising the car. To loosen the nuts, turn thewrench handle counterclockwise. When doingthis, be sure that the socket is seated completelyover the nut so it cannot slip off. For maximumleverage, position the wrench so the handle is tothe left as shown in the drawing. Then, whileholding the wrench near the end of the handle,push down on it with steady pressure. Do notremove the nuts at this time. Just loosen themabout one-half turn.
HGK193
D060C01A-AAT 2. Block the Wheel Block the wheel that is diagonally opposite from the flat to keep the vehicle from rolling when thecar is raised on the jack.
Flat tire
HGK192
Remove the spare tire and remove the jack and tool bag from the trunk.
D060B02GK-AAT 1. Obtain Spare Tire and Tool
HGK189
HGK191
The jack is located behind the right side of luggage trim. Remove the jack cover by un-screwing the bolts. Turn the jack end counter-clockwise to lower the jack height by using ascrew driver or wrench bar and remove it fromthe bracket.

WHAT TO DO IN AN EMERGENCY
3-6
D060E01A-AAT 4. Put the Jack in Place
The base of the jack should be placed on firm, level ground. The jack should be positioned asshown in the drawing.
HGK186D060F02E-AAT 5. Raising the Car After inserting a bar into the wheel nut wrench, install the bar into the jack as shown in thedrawing. To raise the vehicle, turn the jack handleclockwise. As the jack begins to raise the ve-hicle, double check that it is properly positionedand will not slip. If the jack is on soft
ground or
sand, place a board, brick, flat stone or otherobject under the base of the jack to keep it fromsinking.Raise the car high enough so that the fullyinflated spare tire can be installed. To do this, youwill need more ground clearance than is requiredto remove the flat tire. WARNING: Do not get under the car when it is supportedby the jack! This is very dangerous as the jackcould fall and cause serious injury or death.No one should stay in the car while the jack isbeing used.
D060G02Y-AAT 6. Changing Wheels Loosen the wheel nuts and remove them with your fingers. Slide the wheel off the studs and layit flat so it cannot roll away. To put the wheel onthe hub, pick up the spare tire, line up the holeswith the studs and slide the wheel onto them. Ifthis is difficult, tip the wheel slightly and get thetop hole in the wheel lined up with the top stud.Then jiggle the wheel back and forth until thewheel can be slid over the other studs.
HGK232HFC4022
Wrench bar
Wheel nut wrench

CORROSION PREVENTION AND APPEARANCE CARE 4-3
E030D01A-AAT When to Wax AgainYou should polish and wax the car again when water no longer beads on a clean surface butspreads out over a larger area. E030E01A-AAT Maintaining BumpersSpecial precautions must be observed to pre- serve the appearance of the bumpers on yourHyundai. They are:
o Be careful not to spill battery electrolyte or
hydraulic brake fluid on the bumpers. If you do, wash it off immediately with clear water.
o Be gentle when cleaning the bumper sur- faces. They are made of soft plastic and thesurface can be damaged if mistreated. Do notuse abrasive cleaners. Use warm water andmild soap or car-washing solution.
o Do not expose the bumpers to high tem- peratures. For example, if you have your carrepainted, do not leave the bumpers on thecar if the car is going to be placed in a high-temperature paint booth. E040A01A-AAT CLEANING THE INTERIOR To Clean the Vinyl Upholstery To clean the vinyl upholstery, first remove loose dirt and dust with a vacuum cleaner. Then applya solution of mild soap or detergent and waterusing a clean sponge or soft cloth. Allow this tostay on the surface to loosen the dirt, then wipewith a clean damp sponge or cloth. If all the dirtstains are not removed, repeat this procedureuntil the upholstery is clean. Do not use gasoline,solvent, paint thinner or other strong cleaners.
E030B01A-AAT Spot CleaningDon't use gasoline, strong solvents or corrosive cleaning agents. These can damage the finish ofthe car. To remove road tar, use turpentine on aclean, soft cloth. Be gentle.To remove dead insects or tree sap, use warmwater and mild soap or car-washing solution.Soak the spot and rub gently. If the paint has lostits luster, use a commercial car-cleaning polish. E030C01A-AAT Polishing and Waxing Always wash and dry the car before polishing or waxing or using a combination cleaner and wax.Use a good quality commercial product andfollow the manufacturer's directions on the con-tainer. Polish and wax the bright trim pieces aswell as the paint. E040B01A-AAT To Clean the Leather Upholstery (If Installed) In the normal course of use, leather upholstered surfaces will, like any material, pick-up dust anddirt. This dust and dirt must be cleaned off or itmay work into the surface of the leather, causingdamage. Fine leather needs care, and should be cleaned when necessary. Washing leather thoroughlywith soap and water will keep your leather lus-trous, beautiful and ensure you have many yearsof wear.Take a piece of cheese cloth and using any mildsoap and lukewarm water, work up a good lather.Thoroughly wash the leather. Wipe clean with aslightly damp cloth and dry with soft cloth. Do thisas often as the leather becomes soiled.
sure that the outlets and the underside of thedoors are open. Paint damage can be caused bysmall accumulation of tar, industrial precipita-tion, tree resin, insects and bird droppings, whennot removed immediately. If water alone is notstrong enough to remove the accumulated dirt,use a mild car washing solution. Be sure to rinsethe surface after washing to remove the solution.Never allow the solution to dry on the paintedsurfaces.

DO-IT-YOURSELF MAINTENANCE
6-4 G020A01A-AAT
GENERAL CHECKS Engine Compartment
The following should be checked regularly:
o Engine oil level and condition
o Transaxle fluid level and condition
o Brake fluid level
o Clutch fluid level
o Engine coolant level
o Windshield washer fluid level
o Accessory drive belt condition
o Engine Coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level
o Battery condition
o Air conditioner filter condition
G020B01A-AAT
Vehicle Exterior The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut torque
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and body corrosion
o Fluid leaks
o Door and hood lock condition
o Tire pressure and condition (including spare tire) G020C01A-AAT
Vehicle Interior
The following should be checked each time when the vehicle is driven:
o Lights operation
o Windshield wiper operation
o Horn operation
o Defroster, heating system operation (and air conditioning, if installed)
o Steering operation and condition
o Mirror condition and operation
o Turn signal operation
o Accelerator pedal operation
o Brake operation, including parking brake
o Manual transaxle operation, including clutch operation
o Automatic transaxle operation, including "Park" mechanism operation
o Seat control condition and operation
o Seat belt condition and operation
o Sunvisor operation
If you notice anything that does not operate correctly or appears to be functioning incorrect-ly, inspect it carefully and seek assistance fromyour Hyundai dealer if service is needed. G030A01A-AAT
CHECKING THE ENGINE OIL
Engine oil is essential to the performance andservice of the engine. It is suggested that youcheck the oil level at least once a week innormal use and more often if you are on a tripor driving in severe conditions. G030B02GK-GAT
Recommended Oil SH, SG or SG/CD (API) multi-grade and fuel efficient oil is recommended.
SSA6030B°C °F -25-13 20W-40 20W-50
15W-40 15W-50
10W-30
10W-40 10W-50
5W-40
5W-30
5W-2040
104
20 68
1050
032
-15 5 -10-14
1.6L (DOHC), 2.7 L (V6)

DO-IT-YOURSELF MAINTENANCE
6-16 G160A01A-GAT CHECKING CLUTCH PEDAL FREE-PLAY With the engine off, press lightly on the clutch pedal until you feel a change in resistance. Thisis the clutch pedal freeplay. The freeplay shouldbe within the limits specified in the illustration. Ifit is not, have it inspected by your Hyundaidealer and adjusted or repaired if necessary.
SSA6160A
6 ~ 13 mm (0.24 ~ 0.51 in.)
G150A01A-GAT
CHECKING STEERING WHEEL FREEPLAY
To check the steering wheel freeplay, stop the car with the wheels pointed straight ahead andgently move the steering wheel back and forth.Use very light finger pressure and be sensitiveto changes in resistance that mark the limits ofthe freeplay. If the freeplay is greater thanspecified, have it inspected by your Hyundaidealer and adjusted or repaired if necessary.
HGK218
30 mm (1.18in.)
HGK253
HGK254
3. Remove the filter cover.
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 direction
of the arrow sign. Otherwise, it may causenoise or deterioration.

DO-IT-YOURSELF MAINTENANCE
6-18 4. Replace the blown fuse by pressing a new
fuse of the same rating into place. The fuse should be a snug fit. If it is not, have the fuseclip repaired or replaced by a Hyundai dealer.If you do not have a spare fuse, you may beable to borrow a fuse of the same or lowerrating from an accessory you can tempo-rarily get along without (the radio or cigarettelighter, for example). Always remember toreplace the borrowed fuse.
AXA6201B
G200B02A-AAT
Replacing Accessory Fuse The fuse box for the lights and other electrical accessories will be found low on the dashboardon the driver's side. Inside the box you will find alist showing the circuits protected by each fuse. If any of your car's lights or other electrical
accessories stop working, a blown fuse couldbe the reason. If the fuse has burned out, youwill see that the metal strip inside the fuse hasburned through. If you suspect a blown fuse,follow this procedure:
1. Turn off the ignition and all other switches.
2. Open the fuse box and examine each fuse. Remove each fuse by pulling it toward you (a small "fuse puller" tool is contained in thefuse box to simplify this operation).
3. Be sure to check all other fuses even if you find one that appears to have burned out.
HGK185
G200A01A-AAT
CHECKING AND REPLACING FUSES Replacing a Fusible Link
A fusible link will melt if the electrical circuits
from the battery are ever overloaded, thus pre- venting damage to the entire wiring harness.(This could be caused by a short in the systemdrawing too much current.) If this ever happens,have a Hyundai dealer determine the cause,repair the system and replace the fusible link.The fusible links are located in a relay box foreasy inspection.
CAUTION: When replacing a fusible link, never use
anything but a new fusible link with the same or lower amperage rating. Never use apiece of wire or a higher-rated fusible link.This could result in serious damage andcreate a fire hazard.
AS60310A
Good
Bad

DO-IT-YOURSELF MAINTENANCE 6-19
CAUTION: A burned-out fuse indicates that there is a
problem in the electrical circuit. If you re- place a fuse and it blows as soon as theaccessory is turned on, the problem is seri-ous and should be referred to a Hyundaidealer for diagnosis and repair. Never re-place a fuse with anything except a fusewith the same or a lower amperage rating. Ahigher capacity fuse could cause damageand create a fire hazard.
NOTE: See page 6-23 for the fuse panel descrip-
tions.
Burned out
G200B03YGood G210A01A-AAT
CHECKING THE BATTERY
WARNING: Batteries can be dangerous! When working
with batteries, carefully observe the follow- ing precautions to avoid serious injuries.
The fluid in the battery contains a strong solu-
tion of sulfuric acid, which is poisonous andhighly corrosive. Be careful not to spill it onyourself or the car. If you do spill battery fluid onyourself, immediately do the following:
o If battery fluid is on your skin, flush the affected areas with water for at least 15 minutes and then seek medical assistance.
o If battery fluid is in your eyes, rinse out your eyes with water and get medical assistanceas soon as possible. While you are beingdriven to get medical assistance, continueto rinse your eyes by using a sponge or softcloth saturated with water.
o If you swallow battery fluid, drink a large quantity of water or milk followed by milk ofmagnesia, eat a raw egg or drink vegetableoil. Get medical assistance as soon aspossible.
While batteries are being charged (either by a
battery charger or by the vehicle's alternator),they produce explosive gases. Always observethese warnings to prevent injuries from occur-ring: G210B01A-AAT
Checking the Battery Keep the battery clean. Any evidence of corro-
sion around the battery posts or terminals shouldbe removed using a solution of household bak-ing soda and warm water. After the batteryterminals are dry, cover them with a light coat-ing of grease.
G220A01A-AAT
CHECKING ELECTRIC COOLING FANS WARNING: The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper- ate even when the engine is not running.Use extreme caution when working near theblades of the coolant fan, so that you are notinjured by a rotating fan blade. As the cool-ant temperature decreases the fan will auto-matically shut off. This is a normal condi-tion.
G220B01A-AAT
Checking Engine Cooling Fan The engine coolant fan should come on auto-
matically if the engine coolant temperature ishigh.
o Charge batteries only in a well ventilated
area.
o Do not permit flames, sparks or smoking in the area.
o Keep children away from the area.

DO-IT-YOURSELF MAINTENANCE
6-20 G260A02A-AAT
REPLACING LIGHT BULBS
Before attempting to replace a headlight bulb, be sure the switch is turned to the "OFF"position. The next paragraph shows how to reach head- light bulbs so they may be changed. Be sure toreplace the burned-out bulb with one of thesame number and wattage rating. CAUTION: Keep the lamps out of contact with petro-leum products such as oil, gasoline etc. 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.High Beam Low Beam
Turn signal Light
G240A01A-AAT POWER STEERING HOSES It is suggested that you check the power steer- ing hose connections for fluid leakage daily.The power steering hoses should be replaced ifthere is severe surface cracking, pulling, scuff-ing or worn spots. Deterioration of the hosecould cause premature failure. G250A01A-AAT
FOR MORE INFORMATION ABOUT YOUR HYUNDAI
If you desire additional information about main- taining and servicing your Hyundai, you maypurchase a factory Shop Manual at your Hyundaidealer's parts department. This is the samemanual used by dealership technicians andwhile it is highly technical it can be useful inobtaining a better understanding of your carand how it works.
G230A03A-GAT
POWER STEERING FLUID LEVEL
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 cer-tain that the power steering fluid level is be-tween the "MAX" and "MIN" level markings onthe fluid reservoir.
NOTE: Grinding noise from the power steering
pump may be heard immediately after the engine is started in extremely cold condi-tions (below - 20°F). If the noise stops dur-
HGK214
G220C01A-AAT
Checking Condenser Cooling Fan
The condenser coolant fan should come on
automatically whenever the air conditioning is in operation. ing warm up, there is no abnormal functionin the system. It is due to a power steeringfluid characteristic in extremely cold condi-tions. Recommended Fluid Use PSF-3 type fluid NOTE: Do not start the engine when the power steering oil reservoir is empty.

DO-IT-YOURSELF MAINTENANCE 6-21
G290A02GK-GAT
HEADLIGHT AIMING ADJUSTMENT
Horizontal aiming
G290A01GK
Vertical aiming
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 re- placement bulb and install the new bulb by matching the plastic base with the headlighthole. Install the dust cover after retighteningthe bulb spring and reconnect the powercord.
7. Use the protective cap and carton to dis- pose of the old bulb.
8. Check for proper headlight aim.
WARNING: The halogen bulb contains gas under pres-
sure and if impacted could shatter, resulting in flying fragments. Always wear eye pro-tection when servicing the bulb. Protect thebulb against abrasions or scratches andagainst liquids when lighted. Turn the bulbon only when installed in a headlight. Re-place the headlight if damaged or cracked.Keep the bulb out of the reach of childrenand dispose of the used bulb with care.
Before performing aiming adjustment, make sure
of the following.
Low Beam
G290A02GK
Vertical aiming
High Beam
Horizontal aiming1. Keep all tires inflated to the correct pres-
sure.
2. Place the vehicle on level ground and press the front bumper & rear bumper down sev- eral times. Place vehicle at a distance of 3m(118 in.) from the test wall.
3. See that the vehicle is unloaded (except for full levels of coolant, engine oil and fuel, andspare tire, jack, and tools).
4. Clean the head light lenses and turn on the headlights.
5. Open the hood.
6. Draw the vertical line (through the center of each headlight beam pattern) and the hori-zontal line (through the center of each head-light beam pattern) on the aiming screen. And then, draw a parallel line at 30 mm (1.18 in.) under the horizontal line.
7. Adjust each cut-off line of the low beam to the parallel line with a phillips screwdriver -VERTICAL AIMING.
8. Adjust each cut-off line of the low beam to each vertical line with a phillips screwdriver- HORIZONTAL AIMING.

DO-IT-YOURSELF MAINTENANCE
6-22 SPECIFICATION:
"H" Horizontal center line of headlights from ground:Low Beam: 679mm (26.7 in.)High Beam: 672mm (26.5 in.) "W" Distance between each headlight center :Low Beam: 1,202mm (47.3 in.)High Beam: 966mm (38.0 in.) "L" Distance between the headlights and the wall
that the lights are tested against : 3,000 mm (118 in.)
G290B01GK-GAT
Adjustment After Headlight Assembly Replacement
G290B02Y
Vertical line
Cut-off line Ground line
Horizontal line
LW
H
H "P"30 mm ( 1.18 in.)
If the vehicle has had front body repair and the
headlight assembly has been replaced, the headlight aiming should be checked using anaiming screen as shown in the illustration. Turnon the headlight switch.
1. Adjust headlights so that main axis of light is parallel to center line of the body and isaligned with point "P" shown in the illustra-tion.
2. Dotted lines in the illustration show the cen- ter of headlights.