brake Hyundai Coupe 2005 Service Manual

6
DO-IT-YOURSELF MAINTENANCE
5
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 (in- cluding 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 opera- tion (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, includ-
ing clutch operation
o Automatic transaxle operation, in- cluding "Park" mechanism opera-tion
o Seat control condition and opera-
tion
o Seat belt condition and operation
o Sunvisor operation
If you notice anything that does notoperate correctly or appears to be functioning incorrectly, inspect it care- fully and seek assistance from yourHyundai dealer if service is needed.
G020A01A-AAT
Engine Compartment
The following should be checked regu-larly:
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 compo- nents)
o Power steering fluid level
o Battery condition
o Air filter condition GENERAL CHECKS

6 DO-IT-YOURSELF MAINTENANCE
8CHANGING THE OIL AND FIL- TER
G040A04GK-GAT
o The engine oil consumption is
strongly effected by the viscosity and quality of oil, engine rpm and driving condition etc. More engine oil may be consumed under severedriving conditions such as high speeds, frequent acceleration and deceleration, compared to normaldriving condition.
F040A02TB
G040A03E G040A01B
The engine oil and filter should be
changed at those intervals specifiedin the maintenance schedule in Sec- tion 5. If the car is being driven in severe conditions, more frequent oiland filter changes are required.
The procedure for changing the oil
and filter is as follows:
1. Park the car on level ground and
set the parking brake. Start the engine and let it warm up until the needle on the coolant temperature gauge moves above the lowestmark. Turn the engine off and place the gear selector lever in "P" (auto-
Oil filler cap
1.6L 2.0L 2.7L
Oil filter Drain plug
Oil filler cap
Oil filter Drain plug
Oil filler cap
Oil filter

6
DO-IT-YOURSELF MAINTENANCE
11
HGK4006
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 coolant should be between the "L" and "F" lines on the reservoir when the engine is cool. Ifthe level is below the "L" mark, add engine coolant to bring it up between "L" and "F". If the level is low, inspectfor coolant leaks and recheck the fluid level frequently. If the level drops again, visit your Hyundai dealer for aninspection and diagnosis of the rea- son. G050D02A-AAT
To Change the Engine Coolant
The engine coolant should be changed at those intervals specified in the ve-hicle maintenance schedule in Sec- tion 5.
CAUTION:
Engine coolant can damage the finish of your car. If you spill en- gine coolant on the car, wash it off thoroughly with clean water.
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1. Park the car on level ground, set the parking brake and remove the radiator cap when cool.
2. Be sure your drain receptacle is in place. Open the drain cock on the radiator. Allow all the engine cool-ant to drain from the cooling sys- tem, then securely close the drain cock.
3. Check Section 9 for the capacity of the cooling system in your car.Then, following the manufacturer'sdirections on the engine coolant container, add the appropriate quantity of engine coolant to theradiator. 4. Turn the radiator cap counterclock-
wise without pressing down on it,until it stops. This relieves any pres- sure remaining in the cooling sys- tem. And remove the radiator capby pushing down and turning coun- terclockwise. Now fill the radiator with clean dem- ineralized or distilled water. Con- tinue to add clean demineralized ordistilled water in small quantities until the fluid level stays up in the radiator neck. G050D03E

6
DO-IT-YOURSELF MAINTENANCE
17
HGK5007
HGK3025
G110D02Y-AAT
To Check the Transaxle Fluid Level
Park the car on level ground with the parking brake engaged. When the transaxle fluid level is checked, the transaxle fluid should be at normaloperating temperature and the en- gine idling. 1. Open the hood, being careful to
keep hands, long hair and clothing clear of any moving parts.
1.6/2.0L
!
G110C03Y-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 temperature. Thismeans that the engine, radiator, radiator hose, exhaust system etc., are very hot. Exercise great carenot to burn yourself during this procedure. 2.7L
While the engine is idling, apply the
brakes and move the gear selectorlever from "P" to each of its other positions — "R", "N", "D" — and thenreturn to "N" or "P". With the engine still idling: 2. Remove the transaxle dipstick, wipe
it clean, reinsert the dipstick as far as it will go, then remove it again. Now check the fluid level on the dipstick. It should be in the "HOT"range on the dipstick.
3. If the transaxle fluid level is low,
use a funnel to add transaxle fluid through the dipstick tube until the level reaches the "HOT" range. Donot overfill.
G110B04A-AAT
Recommended Fluid
Your Hyundai automatic transaxle isspecially designed to operate with Hyundai Genuine ATF SP-III, DIA- MOND ATF SP-III, SK ATF SP-III orother brands approved by Hyundai Motor Co., Damage caused by a nonspecified fluid is not covered byyour new vehicle limited warranty.

6 DO-IT-YOURSELF MAINTENANCE
18
HGK5008
!WARNING:
The cooling fan is controlled by engine coolant temperature and may sometimes operate even when the engine is not running. Useextreme caution when working near the blades of the cooling fan, so that you are not injured by arotating fan blade. As the engine coolant temperature decreases, the fan will automatically shut off. Thisis a normal condition. Fluid level should be within this
range
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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 your Hyundaidealer. The brakes should be checked and inspected for wear at those intervals specified in thevehicle maintenance schedule in Section 5. G120B01A-AAT
Checking the Brake Fluid Level
WARNING:
Use caution when handling brake
fluid. It can damage your vision ifit gets into your eyes. It will also damage your vehicle's paint ifspilled on it and not removed im- mediately. G120C02A-AAT
Recommended Brake Fluid
Use only hydraulic brake fluid con- forming to DOT 3 or DOT 4 specifica- tions in your braking system. Follow the instructions printed on the con-tainer.

6
DO-IT-YOURSELF MAINTENANCE
19
HGK5013
CHECKING THE CLUTCH FLUID
To add brake fluid, first wipe away
any dirt then unscrew the fluid reser- voir cap. Slowly pour the recom- mended fluid into the reservoir. Do not overfill. Carefully replace the capon the reservoir and tighten. G130A01S-AAT (Manual Transaxle) To Check the Clutch Fluid
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G120E02A-AAT
Adding Brake Fluid
WARNING:
Handle brake fluid carefully. It can damage your vision if it gets into your eyes. Use only DOT 3 or DOT4 specification fluid from a sealed container. Do not allow the fluid can or reservoir to remain openany longer than required. This will avoid entry of dirt and moisture which can damage the brake sys- tem and cause improper opera- tion. The clutch fluid level in the mastercylinder should be checked when performing other under hood services. The system should be checked forleakage at the same time. Check to make certain that the clutch fluid level is always between the "MAX" and"MIN" level markings on the fluid res- ervoir. Fill as required. Fluid loss indi- cates a leak in the clutch systemwhich should be inspected and re- paired immediately. Consult your Hyundai dealer.
G120D01A-AAT
To Check the Fluid Level
The fluid level in the brake fluid reser-voir should be checked periodically.The level should be between the "MIN" and "MAX" marks on the side of the reservoir. If the level is at or below the"MIN" mark, carefully add fluid to bring it up to "MAX". Do not overfill.
HGK5012

6 DO-IT-YOURSELF MAINTENANCE
20
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G130B02A-AAT To Replace the Fluid Recommended brake fluid conform- ing to DOT 3 or DOT 4 specification should be used. The reservoir cap must be fully tightened to avoid con-tamination from foreign matter or moisture. NOTE: Do not allow any other liquids to contaminate the brake fluid. Sealdamage will result.
WARNING:
Use caution when handling brakefluid. It can damage your vision ifyou get it in your eyes. It will also damage your vehicle's paint if spilled on it and not removed im-mediately. G140A01A-AAT
Keeping the Condenser Clean
The air conditioning condenser (and
engine radiator) should be checked periodically for accumulation of dirt, dead insects, leaves, etc. These caninterfere with maximum cooling effi- ciency. When removing such accu- mulations, brush or hose them awaycarefully to avoid bending the cooling fans. AIR CONDITIONING CARE
G140B01A-AAT
Checking the Air Conditioning Operation
1. Start the engine and let it run at
fast idle for several minutes with the air conditioning set at the maxi- mum cold setting.
2. If the air coming out of the in-dash vents is not cold, have the air con-ditioning system inspected by yourHyundai dealer.
CAUTION:
Running the air conditioning sys-
tem for extended periods of timewith a low refrigerant level maydamage the compressor.

6
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

6 DO-IT-YOURSELF MAINTENANCE
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

9 VEHICLE SPECIFICATIONS
2
4395(173)
1760(69.3) 1330(52.4)2530(99.6) 1490(58.7) 1490(58.7)
J010A01GK-GAT MEASUREMENT
Overall length Overall widthOverall height (unladen) Wheel base Wheel tread FrontRear
Type Wheel free play Rack strokeOil pump type Rack and pinion0 ~ 30 mm (0 ~ 1.18 in.) 132 mm (5.20 in.) Vane type
J060A01F-AAT FUEL SYSTEM
J020A01GK-GAT POWER STEERING J030A01GK-GATTIRE
Option
J040A03GK-GAT ELECTRICAL
Item Battery Alternator
mm (in.)
Fuel tank
capacity Imp.gal
12 2.7L
MF 68AH
120A
195/65 R15, 205/55 R16, 215/45 R17
2.0L
MF 68AH 90A
J050A01GK-GAT BRAKE
Dual hydraulic with brake booster Ventilated disc Solid discCable
Type Front brake type Rear brake typeParking brake
US.gal
14.5Liter55
J035A01GK-GAT SPARE TIRE
Standard T125/70 R16 (Temporary)
1.6L
MF 60AH
90A