Hyundai Coupe 2005 Owner's Manual

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DO-IT-YOURSELF MAINTENANCE
23CHECKING THE FREE-PLAY
G150A01A-GAT
STEERING WHEEL
To check the steering wheel free- play, stop the car with the wheels pointed straight ahead and gently move the steering wheel back andforth. Use very light finger pressure and be sensitive to changes in resis- tance that mark the limits of the free-play. If the free-play is greater than specified, have it inspected by your Hyundai dealer and adjusted or re-paired if necessary. 30 mm (1.18in.)
G160A01A-GAT
CLUTCH PEDAL
With the engine off, press lightly on
the clutch pedal until you feel a change in resistance. This is the clutch pedal free-play. The freeplay should be within the limits specified in the illus-tration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary. 6 ~ 13 mm (0.24 ~ 0.51 in.)
G170A01A-GAT BRAKE PEDAL With the engine off, press down on the brake pedal several times to re-duce the vacuum in the brake booster.Then, using your hand, press downslowly on the brake pedal until youfeel a change in resistance. This is the brake pedal free-play. The free- play should be within the limits speci-fied in the illustration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary. 3 ~ 8 mm (0.12 ~ 0.31 in.)
HGK5019 G160A01E HXGS508

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24CHECKING BRAKE PEDAL CLEARANCE
G180A01A-GAT 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. 45.1 mm (1.78 in.)
G190A01A-GAT
CHECKING DRIVE BELTS
Drive belts should be checked peri-
odically for proper tension and ad- justed if necessary. At the same time,belts should be examined for cracks, wear, fraying or other evidence of deterioration and replaced if neces-sary.
Belt routing should also be checked
to be sure there is no interference between the belts and other parts of the engine. After a belt is replaced,the new belt should be adjusted again after two or three weeks to eliminate slack resulting from initial stretchingafter use.
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 5.1~6 mm(0.2~0.24 in.)
HTB186
1.6L
Crankshaft pulley

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G200A01E
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CHECKING AND REPLACING FUSES
G200A01GK-AAT
Replacing a Fusible Link
A fusible link will melt if the electrical circuits from the battery are ever over-loaded, thus preventing 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 sys-tem and replace the fusible link. The fusible links are located in a relay box(1.6L/2.0L) or below the positive(+) post cover of the battery (2.7L) for easy inspection. CAUTION:
When replacing a fusible link, never
use anything but a new fusible link with the same or lower amper-age rating. Never use a piece of wire or a higher-rated fusible link. This could result in serious dam-age and create a fire hazard.
Good G200B02A-AAT Replacing Accessory Fuse The fuse box for the lights and other electrical accessories will be foundlow on the dashboard on the driver's side. Inside the box you will find a list showing the circuits protected by eachfuse.If any of your car's lights or otherelectrical accessories stop working, ablown fuse could be the reason. If the fuse has burned out, you will see that the metal strip inside the fuse hasburned through. If you suspect a blown fuse, follow this procedure:
Bad
HGK4003

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26
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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 "fusepuller" tool is contained in the fuse box to simplify this operation).
3. Be sure to check all other fuses even if you find one that appears to have burned out. 4. Replace the blown fuse by pressing
a new fuse of the same rating intoplace. The fuse should be a snug fit. If it is not, have the fuse clip repaired or replaced by a Hyundaidealer. If you do not have a spare fuse, you may be able to borrow a fuse of the same or lower ratingfrom an accessory you can tempo- rarily get along without (the radio or cigarette lighter, for example). Al-ways remember to replace the bor- rowed fuse. CAUTION:
A burned-out fuse indicates that
there is a problem in the electricalcircuit. If you replace a fuse and it blows as soon as the accessory isturned on, the problem is serious and should be referred to a Hyundai dealer for diagnosis andrepair. Never replace a fuse with anything except a fuse with the same or a lower amperage rating.A higher capacity fuse could cause damage and create a fire hazard.
NOTE: See page 6-40 for the fuse panel
descriptions.
Good
HXDFL1026-1
G200B02L
Burned out

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CHECKING THE BATTERY
G210A01A-AAT
WARNING:
Batteries can be dangerous! When working with batteries, carefullyobserve the following precautions to avoid serious injuries. The fluid in the battery contains a
strong solution of sulfuric acid, which is poisonous and highly corrosive. Be careful not to spill it on yourself or thecar. If you do spill battery fluid on yourself, immediately do the follow- ing: o If battery fluid is on your skin, flush
the affected areas with water for atleast 15 minutes and then seek medical assistance.
o If battery fluid is in your eyes, rinse out your eyes with water and getmedical assistance as soon as possible. While you are being drivento get medical assistance, continue to rinse your eyes by using a sponge or soft cloth saturated withwater.
o If you swallow battery fluid, drink a large quantity of water or milk fol- lowed by milk of magnesia, eat a raw egg or drink vegetable oil. Getmedical assistance as soon as possible.
While batteries are being charged
(either by a battery charger or by the vehicle's alternator), they produce explosive gases. Always observe these warnings to prevent injuries fromoccurring:
o Charge batteries only in a well ven- tilated area.
o Do not permit flames, sparks or
smoking in the area.
o Keep children away from the area.
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G210B01Y-GET
Checking the Battery
Keep the battery clean. Any evidence
of corrosion around the battery posts or terminals should be removed using a solution of household baking sodaand warm water. After the battery terminals are dry, cover them with a light coating of grease.
WARNING:Always read the followinginstructions carefullywhen handling a battery.Keep lighted cigarettesand all other flames orsparks away from the bat- tery. Hydrogen, which is a highly combustible gas, is always present in batterycells and may explode if ignited.
D010B01GK

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CHECKING ELECTRIC COOLING FANS
G220A01A-AAT
WARNING:
The cooling fan is controlled by engine coolant temperature and may sometimes operate even whenthe engine is not running. Use extreme caution when working near the blades of the coolant fan,so that you are not injured by a rotating fan blade. As the coolant temperature decreases the fan willautomatically shut off. This is a normal condition.
Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID.Do not allow battery acid to contact your skin, eyes, clothing or paint finish.If any electrolyte gets intoyour eyes, flush your eyeswith clean water for at least 15 minutes and get imme- diate medical attention. Ifpossible, continue to ap- ply water with a sponge or cloth until medical atten-tion is received.If electrolyte gets on yourskin, thoroughly wash thecontacted area.If you feel a pain or a burn-ing sensation, get medi- cal attention immediately. Wear eye protection when charging or working near a battery. Always provide ventilation when working in an en- closed space.o When lifting a plastic-cased bat- tery, excessive pressure on the case may cause battery acid toleak, resulting in personal in- jury. Lift with a battery carrier or with your hands on oppositecorners.
o Never attempt to charge the bat- tery when the battery cables are connected.
o The electrical ignition system works with high voltage. Never touch these componentswith the engine running or the ignition switched on.

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G220B01A-AAT
Checking Engine Cooling Fan
The engine coolant fan should come on automatically if the engine coolant temperature is high. G220C01A-AAT
Checking Condenser Cooling Fan
The condenser coolant fan should come on automatically whenever the air conditioning is in operation. 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 certain that the power steering fluid level is betweenthe "MAX" and "MIN" level markings on the fluid reservoir. NOTE: Grinding noise from the power steering pump may be heard im-mediately after the engine is started in extremely cold conditions (be- low - 20°F). If the noise stops dur-ing warm up, there is no abnormal function in the system. It is due to a power steering fluid characteris-tic in extremely cold conditions. Recommended Fluid Use PSF-3 type fluid NOTE: Do not start the engine when the power steering oil reservoir isempty.
HGK5011

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High Beam
G290A01GK
G240A01A-AAT POWER STEERING HOSES It is suggested that you check the power steering hose connections for fluid leakage daily. The power steer- ing hoses should be replaced if thereis severe surface cracking, pulling, scuffing or worn spots. Deterioration of the hose could cause prematurefailure. G290A02GK-GAT
HEADLIGHT AIMING AD- JUSTMENT
1. Keep all tires inflated to the correctpressure.
2. Place the vehicle on level ground and press the front bumper & rear bumper down several times. Placevehicle 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, and spare 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 pat- tern) and the horizontal line (through the center of each headlight beampattern) on the aiming screen.And then, draw a parallel line at 30mm (1.18 in.) under the horizontal 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 each vertical line with aphillips screwdriver - HORIZON- TAL AIMING.
Before performing aiming adjustment,
make sure of the following.
G290A02GK
Low Beam
Horizontal aiming Vertical aiming
Horizontal aiming Vertical aiming

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G290B01GK-GAT
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 center line of the body and is aligned with point"P" shown in the illustration.
2. Dotted lines in the illustration show the center of headlights. 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 cen-
ter :
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.)
REPLACEMENT OF LIGHT BULBS
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G260A02A-AAT Before attempting to replace a light bulb, be sure the switch is turned tothe "OFF" position.The next paragraph shows how toreach the light bulbs so they may be changed. Be sure to replace the burned-out bulb with one of the samenumber and wattage rating. See page 6-39 for the wattage descrip- tion.
CAUTION:
Keep the lamps out of contact with petroleum products, such as oil, gasoline, etc.
G290B01HR-1
H
Ground line
30mm (1.18 in.)
L
Cut-off line "P"
Horizontal line
H
W
Vertical line

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HGK5025
8. Remove the protective cap from
the replacement bulb and install the new bulb by matching the plas-
G270A01GK-AAT
Headlight and Front Turn Signal Light
1. Allow the bulb to cool. Wear eye
protection.
2. Open the engine hood.
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. 7. Push the bulb spring to remove the
headlight bulb.
HGK5027
HGK5026