Engine Hyundai Coupe 2004 Workshop Manual

DO-IT-YOURSELF MAINTENANCE 6-7
-15 (5)
-25 (-13) -35 (-31)-45 (-49)
G050A01A-AAT
CHECKING AND CHANGING THE EN- GINE COOLANT
WARNING: Do not remove the radiator cap when the
engine is hot. When the engine is hot, the engine coolant is under pressure and mayerupt through the opening if the cap isremoved. You could be seriously burned ifyou do not observe this precaution. Do notremove the radiator cap until the radiator iscool to the touch. G050B01A-AAT
Recommended Engine Coolant
Use a high quality ethylene-glycol coolant in a
50/50 mix with water. The engine coolant shouldbe compatible with aluminum engine parts.Additional corrosion inhibitors or additives shouldnot be used. The cooling system must be main-tained with the correct concentration and typeof engine coolant to prevent freezing and corro-sion. Never allow the concentration of anti-freeze to exceed the 60% level or go below the35% level, or damage to the cooling systemmay result. For proper concentration when add-ing or replacing the engine coolant, refer to thefollowing table.
HGK187
35% 40%50%60%
G050C01A-AAT
To Check the Coolant Level The coolant level can be seen on the side of the plastic coolant reservoir. The level of the cool-ant should be between the "LOW" and "FULL"lines on the reservoir when the engine is cool.If the level is below the "LOW" mark, addengine coolant to bring it up between "LOW"and "FULL". If the level is low, inspect forcoolant leaks and recheck the fluid level fre-quently. If the level drops again, visit yourHyundai dealer for an inspection and diagnosisof the reason.
7. Refill the crankcase with the recommended
engine oil. Refer to the specification in chap-ter 9 for engine oil capacity.
8. Start the engine and check to be sure no oil is leaking from the drain plug or oil filter.
9. Shut off the engine and recheck the oil level.
NOTE:Always dispose of used engine oil in an
environmentally acceptable manner. It is sug-gested that it be placed in a sealed containerand taken to a service station for maybereclaimation. Do not pour the oil on theground or put it in with the household trash.
WARNING: Used motor oil may cause irritation or can-
cer of the skin if left in contact with the skin for prolonged periods of time. Wash yourhands thoroughly with soap and warm wa-ter as soon as possible after handling usedoil.
Ambient
temperature °C ( °F) Engine Coolant concentration
Antifreezesolution Water
65% 60%50%40%

DO-IT-YOURSELF MAINTENANCE
6-8 4. Turn the radiator cap counterclockwise with-
out pressing down on it, until it stops. This relieves any pressure remaining in the cool-ing system. And remove the radiator cap bypushing down and turning counterclockwise. Now fill the radiator with clean demineral- ized or distilled water. Continue to add cleandemineralized or distilled water in small quan-tities until the fluid level stays up in theradiator neck.
G050D02A-AAT
To Change the Engine Coolant
The engine coolant should be changed at those
intervals specified in the vehicle maintenanceschedule in Section 5.
NOTE: Engine coolant can damage the finish of
your car. If you spill engine coolant on the car, wash it off thoroughly with clean water.
1. Park the car on level ground, set the park- ing brake and remove the radiator cap when cool.
2. Be sure your drain receptacle is in place. Open the drain cock on the radiator. Allowall the engine coolant to drain from thecooling system, then securely close the draincock.
3. Check Section 9 for the capacity of the cooling system in your car. Then, followingthe manufacturer's directions on the enginecoolant container, add the appropriate quan-tity of engine coolant to the radiator.
G050D01A
5. Start the engine, top off the radiator withwater and then add engine coolant to the reservoir until the level is between "L" and"F".
6. Replace the radiator and reservoir caps and check to be sure the drain cocks are fullyclosed and not leaking.
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 en-gine coolant temperature decreases, the fanwill automatically shut off. This is a normalcondition.
G050D02A

DO-IT-YOURSELF MAINTENANCE 6-9
G060A02Y-GAT
SPARK PLUGS
YN60100A
V6
Your engine was originally equipped with plati- num-tipped spark plugs. (For 2.7L only). Platinum-tipped spark plugs will last longer than conventional type spark plugs and can be iden-tified by blue lines on the ceramic shell. NOTE: Do not clean or regap platinum-tipped spark plugs. G060B01GK-GAT
Replacing the Spark Plugs
The spark plugs should be changed at the
intervals specified in the vehicle maintenanceschedule in Section 5 or whenever engine per-formance indicates they should be changed.Symptoms that suggest poor spark plug perfor-mance include engine misfiring under load, lossof fuel economy, poor acceleration, etc. Whenspark plugs are replaced, always use sparkplugs recommended by Hyundai. The use ofother spark plugs can result in loss of perfor-mance, radio interference or engine damage.
NOTE: When replacing the spark plugs, genuine
Hyundai replacement parts are recom- mended. Recommended Spark Plugs:
Type
RC10YC4(CHAMPION) BKR5ES-11(NGK) RC10PYPB4(CHAMPION) PFR5N-11(NGK) RC10YC(CHAMPION) BKR5ES(NGK) RC10YC(CHAMPION) BKR5ES(NGK) Remark
Unleaded
Leaded
1.6/2.0L 2.7L*
2.7L
1.6/2.0L
1.0~1.1 mm (0.039 ~ 0.043 in.)*0.7~0.8 mm (0.028 ~ 0.032 in.)*: leaded one DOHC1.0~1.1 mm (0.039 ~ 0.043 in.)
*0.7~0.8 mm (0.028 ~ 0.032 in.)
* Platinum coated. G060C02GK-GAT
Changing the Spark Plugs
You will find it easier to change spark plugs if
the engine is cold. Always change one spark plug at a time. This helps avoid getting the wiresmixed up.
1. Remove the engine rocker cover.
NOTE: It is recommended that the spark plugs for
2.7L Engines should be changed by an au- thorized Hyundai dealer.
2. Using a clean cloth, remove any dirt that has accumulated around the base of the spark plug so it cannot fall into the cylinder whenthe spark plug is removed.
3. To remove the spark plug cable, pull straight up on the insulated connector, not the cable.Pulling on the cable may damage the carboncore conductor.
HGK256

DO-IT-YOURSELF MAINTENANCE
6-10 G070A02GK-AAT
CHANGING THE AIR CLEANER FIL- TER
To change the filter, unsnap the clips around the cover. When this is done, the cover can belifted off, the old filter removed and the new filterput in its place. Genuine Hyundai ReplacementParts are recommended. CAUTION:
o Operating your vehicle without a proper air cleaner filter in place can result in excessive engine wear.
o Be careful that dust or dirt does not enter the air intake, or damage may result.
o When removing the air cleaner filter, be careful that dust or dirt does not enterthe air intake. These may result in dam-age to the air cleaner filter.
HGK213
WARNING: It is recommended that the engine be cool
or cold when changing the spark plugs. If the engine is hot, you could burn yourselfon the insulated connector, the spark plugor the engine itself.
4. When preparing to remove the old spark plug, guide the socket down over the spark plug, being careful not to damage the ce-ramic insulator.
5. To remove the old spark plug, turn the wrench handle in a counterclockwise direc-tion.
6. To install the new spark plug, guide the socket down over the spark plug, beingcareful not to damage the ceramic insulator. NOTE: Spark plugs should be tightened firmly. Over-
tightening can damage the threads in the aluminum cylinder head. Also, leaving them too loose can cause the spark plug to get very hot and possibly result in damage tothe engine.
7. Replace the cable by pushing the insulated connector directly down onto the electrode. Check to be sure it has snapped into placeand can't fall off.
HGK258HGK257

DO-IT-YOURSELF MAINTENANCE 6-11
G090A01A-GAT
FILLING THE WASHER RESERVOIR The washer fluid reservoir supplies fluid to the windshield washer system. A good quality washer fluid should be used to fill the washer reservoir. The fluid level should bechecked more frequently during inclementweather or whenever the washer system is inmore frequent use. The capacity of the washer reservoir is 3.0 liters (3.2 U.S. quarts). CAUTION:
o Radiator antifreeze (engine coolant) should not be used in the washer system because it will damage the car's finish.
o The washer should not be operated if the washer reservoir is empty. This can dam-age the washer fluid pump.
HGK217
G080A02A-AAT WINDSHIELD WIPER BLADES 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 HyundaiReplacement Parts or their equivalent. CAUTION:
o Do not operate the wipers on dry glass.
This can result in more rapid wear of the wiper blades and may scratch the glass.
o Keep the blade rubber out of contact with petroleum products such as engineoil, gasoline etc.HEF119
Transaxle lubricant in the manual transaxle should
be checked at those intervals specified in the vehicle maintenance schedule in Section 5. Recommended Oil
Use only HYUNDAI GENUINE PARTS MTF
75W/90 (API GL-4) in the manual transaxle.Manual Transaxle Oil Capacity
5 speed : 2.15L (2.27 U.S. quarts) 6 speed : 2.2L (2.32 U.S. quarts) WARNING: It is always better to check the transaxle oil
level when the engine is cool or cold. If the engine is hot, you should exercise great caution to avoid burning yourself on hot engine or exhaust parts. G100A02GK-GAT
CHECKING THE TRANSAXLE OIL (MANUAL)
G110A01E
Filler plug
Drain plug

DO-IT-YOURSELF MAINTENANCE
6-12 G110D02Y-AAT
To Check the Transaxle Fluid Level
HGK174
Park the car on level ground with the parking brake engaged. When the transaxle fluid levelis checked, the transaxle fluid should be atnormal operating temperature and the engineidling.
G110C02Y-GAT
Transaxle Fluid Capacity
The fluid capacity of the automatic transaxle is 7.8 liters (8.2 U.S. quarts). WARNING: The transaxle fluid level should be checked when the engine is at normal operating tem-perature. This means that the engine, radia-tor, exhaust system etc., are very hot. Exer-cise great care not to burn yourself duringthis procedure.
G100B02A-AAT
To Check the Manual Transaxle Fluid Level
SSA6100B
Park the car on level ground with the engine off.
1. Using a wrench of the correct size, loosen the oil filler plug by turning it counterclock- wise and remove it with your fingers.
2. Use your finger or suitable tool to feel inside the hole. The oil level should be at its bottomedge. If it is not, check for leaks beforeadding oil. To refill the transaxle or bring theoil level up,add oil slowly until it reaches theproper level. Do not overfill.
3. Replace the plug and washer, screw it in with your fingers and then tighten securelywith the wrench. G110A02A-AAT CHECKING THE TRANSAXLE FLUID (AUTOMATIC) Transaxle fluid in the automatic transaxle should be checked at those intervals specified in thevehicle maintenance schedule in Section 5. NOTE: Basically automatic transaxle fluid is red color. As driving distance increases, thefluid color turns darkish red gradually. It isnormal condition and you should not usefluid color as a criterion for replacing thetransaxle fluid. You must replace the automatic transaxle fluid in accordance with intervals specifiedin the vehicle maintenances schedule insection 5. G110B03A-AAT
Recommended Fluid
Your Hyundai automatic transaxle is specially
designed to operate with DIAMOND ATF SP-III or SK ATF SP-III. Damage caused by anonspecified fluid is not covered by your newvehicle limited warranty.

DO-IT-YOURSELF MAINTENANCE 6-13
While the engine is idling, apply the brakes and
move the gear selector lever from "P" to each of its other positions — "R", "N", "D" — andthen return to "N" or "P". With the engine stillidling:
1. Open the hood, being careful to keep hands, long hair and clothing clear of any moving parts.
2. Remove the transaxle dipstick, wipe it clean, reinsert the dipstick as far as it will go, thenremove it again. Now check the fluid level onthe dipstick. It should be in the "HOT" rangeon the dipstick.
3. If the transaxle fluid level is low, use a funnel to add transaxle fluid through the dipsticktube until the level reaches the "HOT" range.Do not overfill. 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 cooling fan, so that you are notinjured by a rotating fan blade. As the en-gine coolant temperature decreases, the fanwill automatically shut off. This is a normalcondition. Fluid level should be within this range
HGK249
ÎÎ
DOHC V6
HGK212
G120C02A-AAT
Recommended Brake Fluid
Use only hydraulic brake fluid conforming to
DOT 3 or DOT 4 specifications in your braking system. Follow the instructions printed on thecontainer. G120A01A-AAT
CHECKING THE BRAKES
CAUTION: Because brakes are essential to the safe
operation of the car, it is suggested that they be checked and inspected by yourHyundai dealer. The brakes should bechecked and inspected for wear at thoseintervals specified in the vehicle mainte-nance schedule in Section 5.
G120B01A-AAT
Checking the Brake Fluid Level WARNING: Use caution when handling brake fluid. It
can damage your vision if it gets into your eyes. It will also damage your vehicle's paintif spilled on it and not removed immediately.

DO-IT-YOURSELF MAINTENANCE
6-14 G130B02A-AAT
To Replace the Fluid
Recommended brake fluid conforming to DOT 3 or DOT 4 specification should be used. Thereservoir cap must be fully tightened to avoidcontamination from foreign matter or moisture. NOTE: Do not allow any other liquids to contami- nate the brake fluid. Seal damage will result. WARNING: Use caution when handling brake fluid. It can damage your vision if you get it in youreyes. It will also damage your vehicle's paintif spilled on it and not removed immediately. G140A01A-AAT
AIR CONDITIONING CARE Keeping the Condenser Clean
The air conditioning condenser (and engine radiator) should be checked periodically foraccumulation of dirt, dead insects, leaves, etc.These can interfere with maximum cooling effi-ciency. When removing such accumulations,brush or hose them away carefully to avoidbending the cooling fans.
G120D01A-AAT
To Check the Fluid Level
The fluid level in the brake fluid reservoir should
be checked periodically. The level should be between the "MIN" and "MAX" marks on theside of the reservoir. If the level is at or belowthe "MIN" mark, carefully add fluid to bring it upto "MAX". Do not overfill.
G120E02A-AAT
Adding Brake Fluid WARNING: Handle brake fluid carefully. It can damage your vision if it gets into your eyes. Use onlyDOT 3 or DOT 4 specification fluid from asealed container. Do not allow the fluid canor reservoir to remain open any longer thanrequired. This will avoid entry of dirt andmoisture which can damage the brake sys-tem and cause improper operation. To add brake fluid, first wipe away any dirt thenunscrew the fluid reservoir cap. Slowly pour therecommended fluid into the reservoir. Do notoverfill. Carefully replace the cap on the reser-voir and tighten. G130A01S-AAT
CHECKING THE CLUTCH FLUID (Manual Transaxle)To Check the Clutch Fluid
The clutch fluid level in the master cylinder should be checked when performing other un-der hood services. The system should bechecked for leakage at the same time. Check tomake certain that the clutch fluid level is alwaysbetween the "MAX" and "MIN" level markingson the fluid reservoir. Fill as required. Fluid lossindicates a leak in the clutch system whichshould be inspected and repaired immediately.Consult your Hyundai dealer.
HGK215HGK216

DO-IT-YOURSELF MAINTENANCE 6-15
G140D01S-GAT Checking the Compressor Drive Belt When the air conditioning is being used regular- ly, the compressor drive belt tension should bechecked at least once a month. To check the drive belt tension, press down on the belt halfway between the engine crankshaftand compressor pulleys. Pressing with yourfinger, you should not be able to deflect this beltanymore than 8.0 mm. If you have the instru-ments to check it with a force of 98N (22 lb.),the deflection should be approx. 8.0 mm (0.315inches). If the belt is too loose, have it adjustedby your Hyundai dealer.A/C
CRANK PULLEY
TENSION PULLEY 8mm (0.315 in.)
G140D01GK
V6
DOHC
Auto tensioner
Eng.pulley COMP
G140B01A-AAT
Checking the Air Conditioning Opera- tion
1. Start the engine and let it run at fast idle for
several minutes with the air conditioning set at the maximum cold setting.
2. If the air coming out of the in-dash vents is not cold, have the air conditioning systeminspected by your Hyundai dealer.
CAUTION: Running the air conditioning system for
extended periods of time with a low refriger- ant level may damage the compressor.
G140C01A-AAT
Lubrication To lubricate the compressor and the seals in
the system, the air conditioning should be runfor at least 10 minutes each week. This isparticularly important during cool weather whenthe air conditioning system is not otherwise inuse. B760B01GK-GAT
Replacement of air conditioner filter (If installed)
HGK250
HGK251
1. Remove the mounting screws on the down-
side of the glove box.
2. Open the glove box and remove the mount- ing screws on the upside of the glove box.

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.