engine Hyundai Elantra 2006 Repair Manual

5
VEHICLE MAINTENANCE REQUIREMENTS
5
NO. 1 2 3 4 5678 ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL) ENGINE OIL & FILTER (API Class: CF-4 or ABOVE) See Note(1)
(ACEA Class: B4 or ABOVE)
AIR CLEANER FILTERFUEL FILTER CARTRIDGE TIMING BELT DRIVE BELT (FOR P/STR'G PUMP, ALTERNATOR & A/CON)ALTERNATOR VACUUM PUMPALTERNATOR OIL HOSE & VACUUM HOSEFUEL LINES, FUEL HOSE & CONNECTIONS
F030D01E-GAT R :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.
120
96
R R R R I III
105
84
R I I II
9072
R R R R I II
7560
R I I II
6048
R R R
IIII
45
36
R I I II
3024
R R R
IIII
1512
R I I II
KILOMETERS X 1000MONTHS
See Note (2)
European Community Only Except European Community
DESCRIPTION
Note : (1) EVERY 500 KM OR BEFORE STARTING A LONG TRIP - "I" (2) INSPECT EVERY 7,500KM OR 6 MONTHS AND REPLACE EVERY 15,000KM OR 12 MONTHS.
WHEN REPLACING THE FUEL FILTER CARTRIDGE, USE HYUNDAI GENUINE PARTS.

5VEHICLE MAINTENANCE REQUIREMENTS
6
F030C04E-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
DESCRIPTION
GENERAL MAINTENANCE COOLING SYSTEMCOOLANT MANUAL TRANSAXLE OIL AUTOMATIC TRANSAXLEFLUIDBRAKE HOSES AND LINESBRAKE FLUIDREAR BRAKE DRUMS/LININGS, PARKING BRAKEBRAKE PADS, CALIPERS AND ROTORSEXHAUST PIPE AND MUFFLERSUSPENSION MOUNTING BOLTSSTEERING GEAR BOX, LINKAGE & BOOTS/LOWER ARM BALL JOINTPOWER STEERING PUMP, BELT AND HOSESDRIVE SHAFTS AND BOOTSAIR CONDITIONING REFRIGERANTAIR CONDITIONER FILTER (IN FRONT OF BLOWER UNIT)
NO.
12 3 4 5 6789
101112131415
120 96
I I IIIIIIIIIIII
R
105
84
I I III I IIII I
R
90 72
I I
R I IIIIIIIIII
R
7560
I I III I IIII I
R
60 48
I I IIIIIIIIIIII
R
4536
I I III I IIII I
R
30 24
I I IIIIIIIIIIII
R
1512
I I III I IIII I
R
KILOMETERS X 1000 MONTHS
European Community Only Except European Community
See Note (1)GASOLINE ENGINE DIESEL ENGINE
Note : (1) FOR EVERY 24 MONTHS OR 45,000 KM, WHICHEVER OCCURS FIRST - "R"

5
VEHICLE MAINTENANCE REQUIREMENTS
7
ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS TIMING BELTBRAKE PADS, CALIPERS AND ROTORSREAR BRAKE DRUMS/LININGS/PADS,PARKING BRAKESTEERING GEAR RACK, LINKAGE & BOOTS/LOWER ARM BALL JOINT DRIVESHAFTS & BOOTSMANUAL TRANSAXLE OILAUTOMATICTRANSAXLE FLUIDAIR CONDITIONER FILTER (IN FRONT OF BLOWER UNIT)
European Community Only Except European Community
F040A05E-GAT 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 necessary
R R R R
I I I I
RR REVERY 7,500 KM OR 6 MONTHS MORE FREQUENTLY MORE FREQUENTLY EVERY 60,000 KM OR 48 MONTHSMORE FREQUENTLY MORE FREQUENTLY MORE FREQUENTLY EVERY 15,000 KM OR 12 MONTHS EVERY 100,000 KMEVERY 45,000 KMEVERY 40,000 KM MORE FREQUENTLY
SEVERE DRIVING CONDITIONS A - Repeatedly driving short distance of less than 8km(5miles) in normal temperature or less than 16km(10miles) in freezing temperature
B - Extensive engine idling or low speed driving for long distances
C - Driving on rough, dusty, muddy, unpaved, graveled or saltspread roads
D - Driving in areas using salt or other corrosive materials or in very cold weather
A, B, C, D, E, F, G, H, I, K C, E B, H D, E, F, GC, D, G, H C, D, G, H C, D, E, F, G C, D, E, F A, C, D, E, F, G, H, I, J A, C, E, F, G, H, I C, E DRIVING
CONDITION
MAINTENANCE INTERVALS
MAINTENANCE
OPERATION
MAINTENANCE ITEM
E - Driving in sandy areas
F - Driving in heavy traffic area over 32°C (90°F).
G - Driving ion uphill, downhill, or mountain road
H - 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 170 km/h(100 MPH)K - Frequently driving in stop-and-go conditions
MAINTENANCE UNDER SEVERE USAGE CONDITIONS

5VEHICLE MAINTENANCE REQUIREMENTS
8EXPLANATION OF SCHEDULED MAINTENANCE ITEMS
!
F060M01A-AAT o Engine Oil and Filter The engine oil and filter should be changed at the intervals specified in the maintenance schedule. If the car is being driven in severe conditions,more frequent oil and filter changes are required. F060B01A-AAT
o Drive Belts Inspect all drive belts for evidence of cuts, cracks, excessive wear or oil and replace if necessary. Drive belts should be checked periodically forproper tension and adjusted as neces- sary. F060C01A-AAT
o Fuel Filter
A clogged filter can limit the speed at
which the vehicle may be driven, dam-age the emission system and cause hard starting. If an excessive amountof foreign matter accumulates in the fuel tank, the filter may require re- placement more frequently. After installing a new filter, run the
engine for several minutes, and checkfor leaks at the connections. Fuel fil- ters should be installed by trained technicians. WARNING (Diesel only):
Never work on injection system with engine running or within 30 sec- onds after shutting off engine. Highpressure pump, rail, injectors and high pressure pipes are subject to high pressure even after the enginestopped. The fuel jet produced by fuel leaks may cause serious injury, if it touch the body. People usingpacemakers should not move than 30cm closer to the ECU or wiring harness within the engine roomwhile engine is running, since the high currents in the Common Rail system produce considerable mag-netic fields.
F060D01TB-AAT
o Fuel Lines, Fuel Hoses and
Connections
Check the fuel lines, fuel hoses and
connections for leakage and damage.Replace any damaged or leaking partsimmediately.

5
VEHICLE MAINTENANCE REQUIREMENTS
9
F060H01A-AAT
o Air Cleaner Filter A Genuine Hyundai air cleaner filter is
recommended when the filter is re- placed. F060J01A-AAT
o Spark Plugs Make sure to install new spark plugs of the correct heat range. F070B01A-GAT
o Cooling System Check the cooling system part, such as radiator, coolant reservoir, hosesand connections for leakage and dam- age. Replace any damaged parts.
F060E01A-AAT
o Timing Belt
Inspect all parts related to the timing belt for damage and deformation. Replace any damaged parts immedi- ately. F060G01A-AAT
o Vapor Hose and Fuel Filler Cap
The vapor hose and fuel filler cap should be inspected at those inter- vals specified in the maintenanceschedule. Make sure that a new va- por hose or fuel filler cap is correctly replaced. F060F01A-AAT
o Vacuum, Crankcase Ventila-
tion Hoses
Inspect the surface of hoses for evi-
dence of heat and/or mechanical dam- age. Hard and brittle rubber, crack- ing, tears, cuts, abrasions, and ex-cessive swelling indicate deteriora- tion. Particular attention should be paid to examine those hose surfacesnearest to high heat sources, such as the exhaust manifold.
Inspect the hose routing to assure that
the hoses do not come in contact withany heat source, sharp edges or mov- ing component which might cause heatdamage or mechanical wear. Inspect all hose connections, such as clamps and couplings, to make sure they aresecure, and that no leaks are present. Hoses should be replaced immedi- ately if there is any evidence of dete-rioration or damage. F060N02E-GAT
o Valve Clearance
Inspect excessive valve noise and/or engine vibration and adjust if neces- sary. A qualified technician shouldperform the operation.

5VEHICLE MAINTENANCE REQUIREMENTS
10
F070F01A-AAT
o Brake Hoses and Lines
Visually check for proper installation, chafing, cracks, deterioration and anyleakage. Replace any deteriorated or damaged parts immediately. F070G02A-AAT
o Brake Fluid
Check brake fluid level in the brake fluid reservoir. The level should be between "MIN" and "MAX" marks on the side of the reservoir. Use onlyhydraulic brake fluid conforming to DOT 3 or DOT 4.
F070H01A-AAT
o Rear Brake Drums/Linings,
Parking Brake
Check the rear brake drums and lin-
ings for scoring, burning, leaking fluid, broken parts, and excessive wear. Inspect the parking brake system in- cluding the parking brake lever andcables. For detailed service proce- dures, refer to the Shop Manual.
F070D01A-AAT
o Manual Transaxle Oil Inspect the manual transaxle oil ac- cording to the maintenance schedule. NOTE: If the oil level is low, check for possible leaks before adding oil.Do not overfill.
F070C02A-AAT
o Coolant The coolant should be changed at the intervals specified in the mainte- nance schedule.
F070E06A-AAT
o Automatic Transaxle Fluid
The fluid level should be in the "HOT" range of the dipstick, after the engine and transaxle are at normal operating temperature. Check the automatictransaxle fluid level with the engine running and the transaxle in neutral, with the parking brake properly ap-plied. Use HYUNDAI GENUINE ATF SP III, DIAMOND ATF SP III, SK ATF SP III or other brands approved byHyundai Motor Co., when adding or changing fluid. Using the wrong ATF may result in damage to the ATM.

5
VEHICLE MAINTENANCE REQUIREMENTS
11
F070L01A-AAT
o Suspension Mounting Bolts
Check the suspension connections for looseness or damage. Retighten to thespecified torque.F070J01A-AAT
o Brake Pads, Calipers and
Rotors
Check the pads for excessive wear,
discs for run out and wear, and cali- pers for fluid leakage.
F070K01A-AAT
o Exhaust Pipe and Muffler
Visually inspect the exhaust pipes,
muffler and hangers for cracks, dete- rioration, or damage. Start the engineand listen carefully for any exhaust gas leakage. Tighten connections or replace parts as necessary. F070M01A-AAT
o Steering Gear Box, Linkage &
Boots/Lower arm Ball Joint
With the vehicle stopped and engine
off, check for excessive free-play in the steering wheel. Check the linkage for bends or damage. Check the dustboots and ball joints for deterioration, cracks, or damage. Replace any dam- aged parts.
F070N01A-AAT
o Power Steering Pump,
Belt and Hoses
Check the power steering pump and
hoses for leakage and damage. Re- place any damaged or leaking parts immediately. Inspect the power steer-ing belt for evidence of cuts, cracks, excessive wear, oiliness and proper tension. Replace or adjust it if neces-sary. F070P01A-AAT
o Driveshafts and Boots
Check the drive shafts, boots andclamps for cracks, deterioration, or damage. Replace any damaged parts and, if necessary, repack the grease. F070Q01A-AAT
o Air Conditioning Refrigerant
Check the air conditioning lines and connections for leakage and damage.Check air conditioning performance according to the relevant shop manual if necessary.

Engine Compartment ................................................... 6-2
General Checks ........................................................... 6-7
Checking the Engine Oil .............................................. 6-8 Changing the Oil and Filter ......................................... 6-11
Checking and Changing the Engine Coolant ..............6-14
Spark Plugs ................................ ................................. 6-17
Changing the Air Cleaner Filte r ...................................6-19
Checking the Transaxle Oil (Manual) ......................... 6-21
Checking the Transaxle Fluid (Automatic) .................6-22
Checking the Brakes .................................................. 6-24
Checking the Clutch Fluid ........................................... 6-26
Air Conditioning Care .................................................. 6-27
Changing the Air Conditioner Filter
(For Evaporator and Blower Unit) ............................ 6-28
Checking Drive Belts ................................................. 6-30
Checking and Replacing Fuses ................................ 6-31
Checking The Battery ................................................ 6-32
Checking The Eclectric Cooling Fans ........................6-34
Power Steering Fluid Level ......................................... 6-34
Removal of Water From The Fuel F ilter..................... 6-35
Headlight Aiming Adjustment ...................................... 6-36
Replacement of Light Bulbs ........................................6-38
Bulb Wattage ............................................................... 6-45
Fuse Panel D escription ............................................... 6-46
DO-IT-YOURSELF MAINTENANCE
6
6

6 DO-IT-YOURSELF MAINTENANCE
2
6
7
8 9 10 11 12 13
1. Power steering fluid reservoir
2. Engine oil filler cap
3. Brake booster
4. Brake fluid reservoir
5. Clutch fluid reservoir (If installed) 6. Windshield washer fluid reservoir
cap
7. Engine coolant reservoir
8. Engine oil level dipstick
9. Radiator cap 10.Automatic transaxle fluid level
dipstick (If installed)
11.Air cleaner filter
12.Battery
13.Relay box G010B01E
G010B01E-GAT (1.6 DOHC)
CAUTION:
When inspecting or servic-
ing the engine, you should handle tools and other heavy objects carefully so that the plastic cover of theengine is not damaged.
!
ENGINE COMPARTMENT
1 2345

6
DO-IT-YOURSELF MAINTENANCE
3
G010C01E-GAT
(1.8 DOHC)
G010D01E
1. Power steering fluid reservoir
2. Engine oil filler cap
3. Brake booster
4. Brake fluid reservoir
5. Clutch fluid reservoir (If installed) 6. Windshield washer fluid reservoir
cap
7. Engine coolant reservoir
8. Engine oil level dipstick
9. Radiator cap 10.Automatic transaxle fluid level
dipstick (If installed)
11.Air cleaner filter
12.Battery
13.Relay box CAUTION:
When inspecting or servic-ing the engine, you shouldhandle tools and other heavy objects carefully so that the plastic cover of theengine is not damaged.
!
12 3
45
6 7 8 9 10 11 12 13