maintenance Hyundai Getz 2003 Service Manual

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G110D02A-GAT To Check the Transaxle Fluid Level Park the car on level ground with the parking brake engaged. When the transaxle fluid level is checked, thetransaxle fluid should be at normal operating temperature and the engine idling. While the engine is idling, apply the brakes and move the gear selectorlever from "P" to each of its other positions -- "R", "N", "D", "2", "L" -- and then return to "N" or "P". With theengine still idling: 3. If the transaxle fluid level is low, use
a funnel to add transaxle fluid throughthe dipstick tube until the levelreaches the "HOT" range. Do not overfill. WARNING:
The cooling fan is controlled by en- gine coolant temperature and maysometimes operate even when the engine is not running. Use extreme caution when working near theblades of the cooling fan, so that you are not injured by a rotating fan blade. As the engine coolant temper-ature decreases, the fan will auto- matically shut off. This is a normal condition.
C090A03FC
Fluid level should be within "HOT" range
HTB164 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 faras 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.
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WARNING (Diesel only):
Never work on injection system with engine running or within 30 secondsafter shutting off engine. High pres- sure pump, rail, injectors and high pressure pipes are subjected to highpressure even after the engine has been switched off. The fuel jet pro- duced by fuel leaks may cause seri-ous injury, if it contacts with the body. People using pacemakers should not move closer than 30cm tothe ECU or wiring harness within the!

DO-IT-YOURSELF MAINTENANCE 6- 21
G120A01A-AAT CHECKING THE BRAKES G120B01A-AATChecking the Brake Fluid Level
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CAUTION:
Because brakes are essential to the safe operation of the car, it is sug- gested that they be checked andinspected by your Hyundai dealer. The brakes should be checked and inspected for wear at those inter-vals specified in the vehicle mainte- nance schedule in Section 5. WARNING:
Use caution when handling brake fluid. It can damage your vision if it gets into your eyes. It will also dam- age your vehicle's paint if spilledon it and not removed immediately.
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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. G120D01A-AAT To Check the Fluid Level
HTB166
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 thereservoir. If the level is at or below the "MIN" mark, carefully add fluid to bring it up to "MAX". Do not overfill.
engine room with the engine run- ning, since the high currents in the Common Rail system produce con- siderable magnetic fields.

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G140A01A-AAT AIR CONDITIONING CARE Keeping the Condenser Clean The air conditioning condenser (and engine radiator) should be checked periodically for accumulation of dirt,dead insects, leaves, etc. These can interfere with maximum cooling effi- ciency. When removing such accumu-lations, brush or hose them away care- fully to avoid bending the cooling fans.
G140B01A-AAT Checking the Air Conditioning Operation
1. Start the engine and let it run at a 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 condi-tioning system inspected by yourHyundai dealer. G140C01A-AAT Lubrication To lubricate the compressor and the seals in the system, the air condition-ing should be run for at least 10 min- utes each week. This is particularly important during cool weather whenthe air conditioning system is not oth- erwise in use. G140D01TB-GAT Checking the Compressor Drive Belt
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CAUTION:
Running the air conditioning sys- tem for extended periods of timewith a low refrigerant level may damage the compressor. G140D01TB
Power steering
Crank pully
A/C pully
5 ~ 5.5 mm (0.19 ~ 0.21 in.)
1.1L
G120E01TB-AAT Adding Brake Fluid
WARNING:
Handle brake fluid carefully. It can damage your vision if it gets intoyour eyes. Use only DOT 3 or DOT 4 specification fluid from a sealed container. Do not allow the fluidcan or reservoir to remain open any longer than required. This will pre- vent entry of dirt and moisture whichcan damage the brake system and cause improper operation.
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To add brake fluid;
1) If it is necessary, remove the air cleaner cover.
2) Wipe away any dirt then unscrew the fluid reservoir cap.
3) Slowly pour the recommended fluid
into the reservoir using by a funnel. Do not overfill.
4) Carefully replace the cap on the res-
ervoir and tighten.

DO-IT-YOURSELF MAINTENANCE 6- 23
CRANK PULLEY
When the air conditioning is being used regularly, the compressor drive belt tension should be checked at least once a month.To check the drive belt tension, press down on the belt halfway between the engine crankshaft and compressorpulleys. Pressing with your finger, you should not be able to deflect this belt anymore than 8.0 mm (1.1L: 5~ 5.5mm). If you have the instruments to check it with a force of 98N (22 lb.), the deflection should be approx. 8.0 mm(0.315 in.). If the belt is too loose, have it adjusted by your Hyundai dealer. HTB219
A/C
TENSION PULLEY 8mm (0.315 in.)
1.3/1.6L
HTB290
B145A01TB-GAT CHANGING THE AIR FILTER
(In Front of evaporator unit)(If Installed) The air filter is located in front of the evaporator unit behind the glove box. It operates to decrease pollutants fromentering the car and to filter the air.
HTB291
2. Remove the cable and the wiring from the filter cover.
1. Remove the adjusting pins on both sides of the glove box to open halfthe glove box.
HTB292
3. Remove the filter cover to push the upside of the filter cover.

6- 24 DO-IT-YOURSELF MAINTENANCE
HTB293
4. Replace the two filters.
CAUTION:
Be sure to install the air filter in the direction of the arrow sign. Unless, it may cause noise or deterioration.
5. Installation is the reverse order of disassembly.
G150A01A-GAT CHECKING STEERING WHEEL FREEPLAY To check the steering wheel freeplay, stop the car with the wheels pointed straight ahead and gently move thesteering wheel back and forth. Use very light finger pressure and be sen- sitive to changes in resistance thatmark the limits of the freeplay. If the freeplay is greater than specified, have it inspected by your Hyundai dealerand adjusted or repaired if necessary. HTB161
30 mm (1.18 in.)G160A01A-GAT CHECKING CLUTCH PEDAL FREEPLAY
G160A01E
6 ~ 13 mm (0.24 ~ 0.51 in.)
With the engine off, press lightly on the clutch pedal until you feel a change in resistance. This is the clutch pedalfreeplay. The freeplay should be within the limits specified in the illustration. If it is not, have it inspected by yourHyundai dealer and adjusted or re- paired if necessary.
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DO-IT-YOURSELF MAINTENANCE 6- 25
Water Pump Pulley
Alternator Pulley
Crankshaft Pulley 5.1~6 mm(0.2~0.24 in.)
G190A01A-GAT CHECKING DRIVE BELTS (Gasoline)
G180A01A-GAT CHECKING BRAKE PEDAL CLEARANCE
G180A01L
45.1 mm (1.78 in.)
You need a helper to check the brake pedal clearance. With the engine run- ning, have your helper press down on the brake pedal several times and thenhold it down with a force of about 490 N (50 Kg, 110 lbs). The brake pedal clearance is the distance from the topsurface of the brake pedal to the as- phalt sheeting under the floor mat. If the brake pedal clearance is notwithin the limits specified in the illustra- tion, have it inspected by your Hyundai dealer and adjusted or repaired if nec-essary. HTB186
1.1L
1.3L/1.6L Crankshaft pulley
Alternator
HTB220
Water Pump Pulley
9.5 ~11.0 mm (0.37 ~ 0.43 in.)
G170A01A-GAT CHECKING BRAKE PEDAL FREEPLAY
HXGS508
3 ~ 8 mm (0.12 ~ 0.31 in.)
With the engine off, press down on the brake pedal several times to reduce the vacuum in the brake booster.Then, using your hand, press down slowly on the brake pedal until you feel a change in resistance. This is thebrake pedal freeplay. The freeplay should be within the limits specified in the illustration. If it is not,have it inspected by your Hyundai dealer and adjusted or repaired if nec- essary.

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Drive belts should be checked periodi- cally for proper tension and adjusted if necessary. At the same time, beltsshould be examined for cracks, wear, fraying or other evidence of deteriora- tion and replaced if necessary.Belt routing should also be checked to be sure there is no interference be- tween the belts and other parts of theengine. After a belt is replaced, the new belt should be adjusted again after two or three weeks to eliminateslack resulting from initial stretching after use. G200A01A-AAT CHECKING AND REPLACING FUSESReplacing a Fusible Link
G200A01L
Melted
Good
G190B01TB-GAT CHECKING DRIVE BELTS (Diesel)
A/C comp.
Auto tensioner Pulley
G190B01TB
AlternatorPower steering pump
At the scheduled maintenance inspec- tion, belts should be examined forcracks, 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 be- tween the belts and other parts of theengine. A fusible link will melt if the electricalcircuits from the battery are ever over-loaded, thus preventing damage to the entire wiring harness. (This could be caused by a short in the system draw-ing too much current.) If this ever happens, have a Hyundai dealer de- termine the cause, repair the systemand replace the fusible link. The fusible links are located in a fuse box for easy inspection.

DO-IT-YOURSELF MAINTENANCE 6- 27
CAUTION:
When replacing a fusible link, never use anything but a new fusible link with the same or lower amperage rating. Never use a piece of wire ora higher-rated fusible link. This could result in serious damage and create a fire hazard.!
4. Replace the blown fuse by pressing a new fuse of the same rating into place. The fuse should be a snug fit. If it is not, have the fuse clip repairedor replaced by a Hyundai dealer. If you do not have a spare fuse, you may be able to borrow a fuse of thesame or lower rating from an acces-
G200B02A-AAT Replacing Accessory Fuse The fuse box for the lights and other electrical accessories will be found low on the dashboard on the driver's side.Inside the box you will find a list show- ing the circuits protected by each fuse. If any of your car's lights or otherelectrical accessories stop working, a blown fuse could be the reason. If the fuse has burned out, you will see thatthe metal strip inside the fuse has burned through. If you suspect a blown fuse, follow this procedure:
HTB180
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 "fuse puller" tool is contained in the fusebox to simplify this operation).
3. Be sure to check all other fuses
even if you find one that appears tohave burned out.
HTB223

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sory you can temporarily get along without (the radio or cigarette light- er, for example). Always rememberto replace the borrowed fuse. CAUTION:
A burned-out fuse indicates thatthere is a problem in the electricalcircuit. If you replace a fuse and it blows as soon as the accessory is turned on, the problem is seriousand should be referred to a Hyun- dai dealer for diagnosis and repair. Never replace a fuse with anythingexcept a fuse with the same or a lower amperage rating. A higher capacity fuse could cause damageand create a fire hazard. NOTE: See page 6-38 for the fuse panel descriptions.
! G210A01A-AAT CHECKING THE BATTERY
WARNING:
Batteries can be dangerous! When working with batteries, carefully ob-serve the following precautions to avoid serious injuries. HTB165
The fluid in the battery contains astrong solution of sulfuric acid, which is poisonous and highly corrosive. Becareful not to spill it on yourself or the car. If you do spill battery fluid on yourself, immediately do the following:
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DO-IT-YOURSELF MAINTENANCE 6- 29
o If battery fluid is on your skin, flush
the affected areas with water for at least 15 minutes and then seekmedical assistance.
o If battery fluid is in your eyes, rinse
out your eyes with water and getmedical assistance as soon as pos- sible. While you are being driven to get medical assistance, continue torinse your eyes by using a sponge or soft cloth saturated with water.
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 pos- sible.
While batteries are being charged (ei-ther by a battery charger or by the vehicle's alternator), they produce ex-plosive gases. Always observe these warnings to prevent injuries from oc- curring:
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. G220B01A-AAT Checking Engine Cooling Fan The engine coolant fan should come on automatically if the engine coolanttemperature is high. G220C01TB-AAT Checking Condenser Cooling Fan When the air conditioning is in opera- tion, the condenser cooling fan comes on automatically to be controlled by ECU.
G210B01A-AAT Checking the Battery Keep the battery clean. Any evidence of corrosion around the battery postsor terminals should be removed using a solution of household baking soda and warm water. After the battery ter-minals are dry, cover them with a light coating of grease. G220A01A-AAT CHECKING ELECTRIC COOL- ING FANS
WARNING:
The cooling fan is controlled by engine coolant temperature andmay sometimes operate even when the engine is not running. Use ex- treme caution when working nearthe blades of the coolant fan, so that you are not injured by a rotat- ing fan blade. As the engine cool-ant temperature decreases the fan will automatically shut off. This is a normal condition.
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