steering Hyundai Coupe 2005 Workshop Manual

2DRIVING YOUR HYUNDAI
18
In addition, anti-freeze solution must ALWAYS be used in vehicles fittedwith air conditioning, to prevent the heater matrix from freezing and sub- sequently bursting with the refrigera-tion system in use.
ZC170D1-E Door Locks Should the door lock mechanism be- come frozen, a proprietary lock de-icer should be used. Never attempt to thaw a frozen doorlock using hot water, since the water will eventually freeze and compound the problem. SC170E1-E Windscreen Washers and Wip- ers The windscreen washer bottle should be filled with a solution of water and a proprietary winter screen wash addi-tive. The windscreen wipers should not be used if the blades are frozen to the windscreen or if they are coveredwith snow, before this is removed. NOTE: Never allow undiluted screen washer fluid additive to spill upon the paintwork or use engine cool- ant anti-freeze since damage to thepaintwork may result.
o When driving in extreme conditions,
the windscreen wiper blades may fail to clear the screen properly due to the formation of ice upon theblade edge. It will therefore be nec- essary to periodically remove such ice to restore their efficiency.
o If the power operated door mirrors become frozen, attempts to adjustthese may damage the mechanism. o The formation of snow or ice built up
inside the wheel arches may inter-fere with the road wheels or steering mechanism. In such instances, un- usual noises or an increase in steer-ing effort may result. Therefore, ensure that the wheel arches are checked periodically and any accu-mulated snow or ice removed.
o It is advisable to carry emergency
equipment including, torch, shovel,tow rope, blankets etc., if a journey is to be undertaken into areas of severe road conditions.
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3
IN CASE OF EMERGENCY
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SD070K1-E AFTER CHANGING WHEELS The pressure of the spare tyre should be checked at the first available oppor-tunity. If any doubt exists as to the tyre pressure, the vehicle should be driven slowly to the nearest service stationand the tyre pressure checked and adjusted as required. If the valve cap is lost from any of thevalves, a replacement should be ob- tained and fitted at the first available opportunity. The valve cap preventsthe ingress of dirt which may cause the valve to stick and therefore leak and is part of the valve sealing function. Ensure that the spare wheel, jack and wheel nut wrench as well tools are correctly located in the boot of the vehicle to prevent damage and noise. HGK4032
IF YOUR VEHICLE MUST BE TOWED
D080A01E-EAT If your vehicle has to be towed, it should be done by your Hyundaiauthorised repairer or a commercial tow truck service. This will help assure that your vehicle is not damaged in towing.Also, professionals are generally aware of local laws governing towing. In any case, rather than risk damage to yourcar, it is suggested that you show this information to the tow truck operator. Be sure that a safety chain system isused and that all local laws are ob- served. It is recommended that your vehiclebe towed with a wheel lift and dollies or flatbed equipment with all the wheels off the ground.
! CAUTION:
o Your vehicle can be damaged if towed incorrectly!
o Be sure the transaxle is in neu- tral.
o When the engine will not start, be sure the steering is unlocked by placing the key in the "ACC" po- sition.
D080B01O-GAT Towing the Vehicle
HGK4030
Your vehicle can be towed by wheel lift type truck (1), (2) or flatbed equipment (3). 1)
2)
3)
dolly
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3
IN CASE OF EMERGENCY
13
HGK4018
D080D03A-EAT Emergency Towing For emergency towing when no com- mercial tow vehicle is available, attach a tow cable, chain or strap to one of the towing hooks under the front/rear ofyour car. Do not attempt to tow your vehicle in this manner on any unpaved surface. This could result in seriousdamage to your car. Nor should towing be attempted if the wheels, drive train, axles, steering orbrakes are damaged. Before towing, be sure the transaxle is in neutral and the key is in "ACC" (with the engine off)or in the "ON" position (with the engine running). A driver must be in the towed car to steer it and operate the brakes. Front
Rear
!CAUTION:
o If the car is being towed with all four wheels on the ground, it can be towed only from the front. Be sure that the transaxle is in neu-tral. Do not tow at speeds greater than 30 mph (50 km/h) and for more than 15 miles (25 km).
o Be sure the steering is unlocked by placing the key in the "ACC"position.
IF YOU LOSE YOUR KEYS
D120A01A-GAT If you lose your keys, many Hyundai dealers can make you a new key if you have your key number. If you lock the keys inside your car and you cannotobtain a new key, many Hyundai deal- ers can use special tools to open the door for you. Information about the keyof immobilizer system (If Installed) will be found on page 1-4.
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5
VEHICLE MAINTENANCE REQUIREMENTS
5
NO. 1 2345 6 789
1011 12 1314151617 18 192021 DESCRIPTION
GENERAL MAINTENANCECOOLING SYSTEM COOLANT COOLANT SPECIFIC GRAVITYMANUAL TRANSAXLE OILAUTOMATIC TRANSAXLE FLUIDBRAKE PIPES, HOSES, AND CONNECTIONSBRAKE FLUID CLUTCH FLUID REAR BRAKE LININGS AND CYLINDERSBRAKE PADSSUSPENSION AND STEERING SYSTEMFRONT SUSPENSION BALL JOINTSPOLLEN FILTER (For Blower unit) REAR WHEEL BEARINGS TYRE CONDITION AND PRESSURE (incl. Spare)LUBRICATE LOCKS AND HINGESCHECK ALL ELECTRICAL SYSTEMSROAD TESTCHECK ALL SYSTEMS WITH HI-SCAN CHECK 4 GAS DRIVE SHAFT & BOOT
F030C03GK-EAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
60 72
I I I
R
I
RR IIII
R I I IIIII I
50 60
I I IIIII I II
R
I I IIIII I
40 48
I I III
RR IIII
R I I IIIII I
30 36
I I IIIII I II
R I I IIIII I
20 24
I I III
RR IIII
R I I IIIII I
10 12
I I IIIII I II
R
I I IIIII I
MILES X 1000 MONTHS
NOTE : (1)
FOR THE FIRST TIME, REPLACE THE COOLANT AT 60,000 MILES OR 60 MONTHS. AFTER THAT, REPLACE IT EVERY 30,000 MILES OR 24 MONTHS. See Note (1)
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5VEHICLE MAINTENANCE REQUIREMENTS
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ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS TIMING BELT BRAKE PADS, CALIPERS AND ROTORS REAR BRAKE DRUMS/LININGS, PARKING BRAKE STEERING GEAR BOX, LINKAGE & BOOTS/ LOWER ARM BALL JOINT DRIVESHAFTS & BOOTS MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLE FLUID POLLEN FILTER(FOR BLOWER UNIT)
F040A04GK-EAT The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals. R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessaryMAINTENANCE UNDER SEVERE USAGE CONDITIONS
MAINTENANCE INTERVALS
A, B, C, D, E, F, G, H, I, K C, E B, H D, E, F, G C, D, G, H C, D, G, H C, D, E, F C, D, E, F, G A, C, D, E, F, G, H, I, J A, C, E, F, G, H, I C, E
MAINTENANCE ITEMDRIVING
CONDITION
EVERY 4,500MILES OR 6 MONTHS MORE FREQUENTLY MORE FREQUENTLY EVERY 37,000MILES OR 48MONTHS MORE FREQUENTLY MORE FREQUENTLY MORE FREQUENTLYEVERY 9,000MILES OR 12 MONTHS EVERY 60,000MILES EVERY 27,000MILES MORE FREQUENTLY
R R R R II II
R R R
MAINTENANCE
OPERATION
SEVERE DRIVING CONDITIONS
A - Repeatly driving short distance of less than 5miles(8km) in normal temperature or less than 10miles(16km) in freezing temperature
B - Extensive engine idling or low speed driving for long distances
C - Driving on rough, dusty, muddy, unpaved, graveled or salt- spread roads
D - Driving in areas using salt or other corrosive materials or in very cold weather E - Driving in sandy areas
F - Driving in heavy traffic area over 90°F(32°C)G - Driving on uphill, downhill, or mountain roadH - Towing a Trailer, or using a camper, or roof rack
I - Driving as a patrol car, taxi, other commercial use or vehicle towing
J - Driving over 100 MPH(170 Km/h) K - Frequently driving in stop-and-go conditions
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5VEHICLE MAINTENANCE REQUIREMENTS
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6ZF070M1-A
o Steering gear box, linkage &boots/lower arm ball joint
With the vehicle stopped and engine off, check for excessive freeplay in the steering wheel. Check the linkage for bends or dam- age. Check the dust boots and ball joints for deterioration, cracks, or dam- age. Replace any damaged parts. 6ZF070N1-A
o Power steering pump, belt and hoses
Check the power steering pump and hoses for leakage and damage. Re- place any damaged or leaking partsimmediately. Inspect the power steer- ing belt for evidence of cuts, cracks, excessive wear, oil contamination andproper tension. Replace or adjust it if necessary. 6ZF070P1-A
o Drive shafts and boots
Check the drive shafts, boots and
clamps for cracks, deterioration, ordamage. Replace any damaged parts and, if necessary, repack the grease.
6ZF070Q1-A
o Air conditioning refrigerant
Check the air conditioning lines and
connections for leakage and damage. Check air conditioning performance according to the relevant shop manualif necessary.
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6
Engine Compartment ................................................... 6-2
Daily Operating Checks ............................................... 6-5
Engine Oil ..................................................................... 6-5
Engine Oil and Filter Replacement .............................. 6-8 Engine Coolant Checking and Replacing................... 6-10
Changing the Air Cleaner Filte r ...................................6-12
Manual Transaxle Lubricant .................... ....................6-15
Automatic Transaxle Lubricant ................................... 6-16
Brake System Checking ............................................. 6-18
Air Conditioning System Maintenance ........................ 6-20
Changing the Pollen Filte r ........................................... 6-22
Checking Engine Drive Belts ...................................... 6-24
Fusible Links ............................................................... 6-25
Battery Mai ntenance ................................................... 6-26
Power Steering Hoses ................................................ 6-27
Headlight Aiming Adjustment ...................................... 6-28
Replacing Light Bulbs ................................................. 6-30
Bulb Wattage ............................................................... 6-37
Fuse Panel D escription ............................................... 6-38
OWNER MAINTENANCE
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6OWNER MAINTENANCE
2
1. Clutch fluid reservoir
(Not all models)
2. Engine oil filler cap
3. Brake booster
4. Brake fluid reservoir
5. Relay box
G010A01GK-EAT ENGINE COMPARTMENT (1.6L)
ENGINE COMPARTMENT
HGK5003-E
CAUTION:
When inspecting or servic-
ing the engine, you should handle tools and other heavy objects carefully so that the plastic rocker coverof the engine is not dam- aged.
!
6. Windscreen washer fluid reservoir cap
7. Power steering fluid reservoir
8. Engine coolant reservoir
9. Engine oil level dipstick
10.Radiator cap 11.Automatic transaxle fluid level dip-
stick (Not all models)
12.Air cleaner
13.Battery
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OWNER MAINTENANCE
3
G010A01GK-EAT
ENGINE COMPARTMENT (2.0L)
1. Clutch fluid reservoir (Not all mod- els)
2. Engine oil filler cap
3. Brake booster
4. Brake fluid reservoir
5. Relay box 6. Windscreen washer fluid reservoir
cap
7. Power steering fluid reservoir
8. Engine coolant reservoir
9. Engine oil level dipstick 10.Radiator cap
11.Automatic transaxle fluid level dip-
stick (Not all models)
12.Air cleaner
13.Battery CAUTION:
When inspecting or servic- ing the engine, you shouldhandle tools and other heavy objects carefully so that the plastic rocker coverof the engine is not dam- aged.
!
HGK5002-E
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6OWNER MAINTENANCE
4
1. Power steering fluid reservoir
2. Clutch fluid reservoir (Not all mod-els)
3. Brake booster
4. Brake fluid reservoir
5. Air filter element 6. Relay box
7. Windscreen washer fluid reservoir
cap
8. Engine coolant reservoir
9. Engine oil level dipstick 10.Radiator cap
11.Engine oil filler cap
12.Automatic transaxle fluid level dip-
stick (Not all medels)
13.Battery
G010B01GK-EAT
(2.7L)
HGK5001-E
CAUTION:
When inspecting or servic-ing the engine, you shouldhandle tools and other heavy objects carefully so that the plastic rocker coverof the engine is not dam- aged.
!
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