Power Hyundai Getz 2005 Workshop Manual

3- 4 WHAT TO DO IN AN EMERGENCY
D030A02TB-AAT IF THE ENGINE OVERHEATS If your temperature gauge indicates overheating, you experience a loss of power, or hear loud pinging or knock- ing, the engine is probably too hot. Ifthis happens to you, you should:
1. Pull off the road and stop as soon as
it is safe to do so.
2. Place the gear selector lever in "P"
(automatic), or neutral (manual transaxle) and set the parking brake. If the air conditioning is on, turn it off.
6. Carefully remove the jumper cables
in the reverse order of attachment.
If you do not know why your battery became discharged (because the lights were left on, etc.), have the chargingsystem checked by your Hyundai dealer. 3. If engine coolant is running out un-
der the car or steam is coming out from the hood, stop the engine. Donot open the hood until the engine coolant has stopped running or the steaming has stopped. If there is novisible loss of engine coolant and no steam, leave the engine running and check to be sure the enginecooling fan is operating. If the fan is not running, turn the engine off.
4. Check to see if the water pump drive
belt is missing. If it is not missing,check to see that it is tight. If the drive belt seems to be satisfactory,check for coolant leaking from the radiator, hoses or under the car. (If the air conditioning had been in use,it is normal for cold water to be draining from it when you stop). WARNING (Diesel only):
Never work on injection system with engine running or within 30 sec- onds after shutting off engine. High pressure pump, rail, injectors andhigh pressure pipes are subject to high pressure even after the engine stopped. The fuel jet produced byfuel leaks may cause serious in- jury, if it touch the body. People using pacemakers should not movethan 30cm closer to the ECU or wiring harness within the engine room while engine is running, sincethe high currents in the Common Rail system produce considerable magnetic fields.
WARNING:
While the engine is running, keep hair, hands, and clothing away from moving parts such as the fan anddrive belts to prevent injury.
!
!
5. If the water pump drive belt is bro- ken or coolant is leaking out, stop the engine immediately and call the nearest Hyundai dealer for assis-tance.
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5- 6 VEHICLE MAINTENANCE REQUIREMENTS
GENERAL MAINTENANCE COOLING SYSTEMCOOLANTMANUAL TRANSAXLE OILAUTOMATIC 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 (FOR EVAPORATOR AND BLOWER UNIT)
1234 5 6789
101112131415
Note : FOR THE FIRST TIME, REPLACE THE COOLANT 100,000 KM OR 60 MONTHS. AFTER THAT, REPLACE IT EVERY 45,000 KM OR 24 MONTHS.
F030C04TB-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
120
96
I I I IIII I IIIII I
R
105
84
I I I II
IIIII I
R
90 72
75 60
6048
I I
R
I III I IIIII I
R
I I II I
I I I II I
R
I I II I IIII I IIII
R
45 36
3024
I I I II
IIIII I
R
I I IIIII I IIIII I
R
15 12
I I III I IIII I
R
KILOMETERS X 1000 MONTHS
NO. DESCRIPTION
European Community Only Except European Community
See Note
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5- 10 VEHICLE MAINTENANCE REQUIREMENTS
F070L01A-AAT
o Suspension Mounting Bolts
Check the suspension connections
for looseness or damage. Retighten to the specified torque. F070M01A-AAT
o Steering Gear Box, Linkage &
Boots/Lower arm Ball Joint
With the vehicle stopped and engine
off, check for excessive free-play inthe steering wheel. Check the linkage for bends or damage. Check the dust boots 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.
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.
F070F01A-AAT
o Brake Hoses and Lines Visually check for proper installation, chafing, cracks, deterioration and any leakage. 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 onthe side of the reservoir. Use only hydraulic 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 and cables. For detailed service proce- dures, refer to the Shop Manual.
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6. Do-It-Yourself Maintenance
Engine compartment ...................................................................... 6-2
General checks ................................................................................ 6-6
Checking the engine oil .................................................................... 6-7
Changing the oil and filter ................................................................. 6-9
Checking and changing the engine coolant....................................6-13
Spark plugs .................................................................................... 6-15
Changing the air cleaner filter ......................................................... 6-17
Checking the transaxle oil (Manual)............................................... 6-18
Checking the transaxle fluid (Automatic)....................................... 6-19
Checking the brakes ...................................................................... 6-21
Air conditioning care ....................................................................... 6-22
Checking drive belts ...................................................................... 6-25
Checking and replacing fuses ........................................................ 6-26
Power steering fluid level ............................................................... 6-30
Replacement of bulbs .................................................................... 6-32
Fuse panel description ................................................................... 6-38
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6- 2 DO-IT-YOURSELF MAINTENANCE
HTB160A
1. Windshield washer fluid reservoir cap
2. Auto fuel cut switch (If installed)
3. Engine oil filler cap 4. Brake fluid and clutch fluid
reservoir
5. Air filter element
6. Relay box
7. Power steering fluid reservoir 8. Engine oil level dipstick
9. Radiator cap
10.Engine coolant reservoir
11.Battery
G010A01TB-GAT ENGINE COMPARTMENT (1.1 SOHC)
12 3
456
78 9 10 1 1
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DO-IT-YOURSELF MAINTENANCE 6- 3
G010B01TB-GAT ENGINE COMPARTMENT (1.3 SOHC)
1. Windshield washer fluid reservoir
cap
2. Auto fuel cut switch (If installed)
3. Engine oil filler cap
4. Brake fluid and clutch fluid reservoir 5. Air filter element
6. Relay box
7. Power steering fluid reservoir
(If installed)
8. Engine oil level dipstick 9. Radiator cap
10.Engine coolant reservoir
11.Automatic transaxle fluid level dip-
stick (If installed)
12.Battery HTB086A
123
456
78 91 011
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6- 4 DO-IT-YOURSELF MAINTENANCE
G010B01TB-GAT ENGINE COMPARTMENT (1.6L DOHC)
HTB088A
1. Windshield washer fluid reservoir cap
2. Auto fuel cut switch (If installed)
3. Engine oil filler cap
4. Brake fluid and clutch fluid reservoir 5. Air filter element
6. Relay box
7. Power steering fluid reservoir
(If installed)
8. Engine oil level dipstick 9. Radiator cap
10.Engine coolant reservoir
11.Automatic transaxle fluid level dip-
stick (If installed)
12.Battery
1 2 34
56
789 10 11 12 CAUTION:
When inspecting or servicing the engine,you should handle tools and other heavy objects carefully sothat the plastic rocker cover of the engine is not damaged.
!
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DO-IT-YOURSELF MAINTENANCE 6- 5
G010C01TB-GAT ENGINE COMPARTMENT (DIESEL)
HTB159
1. Windshield washer fluid reservoir cap
2. Engine oil filler cap
3. Fuel filter 4. Brake fluid and clutch fluid reser-
voir
5. Air filter element
6. Relay box 7. Power steering fluid reservoir
8. Engine oil level dipstick
9. Radiator cap
10. Engine coolant reservoir
11. Battery
12
3
45 6
78 910
11 CAUTION:
When inspecting or servicing the engine,you should handle tools and other heavy objects carefully sothat the plastic rocker cover of the engine is not damaged.
!
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6- 6 DO-IT-YOURSELF MAINTENANCE
G020A01A-AAT GENERAL CHECKS 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 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, heater system operation
(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 not operate correctly or appears to befunctioning incorrectly, inspect it care- fully and seek assistance from your Hyundai dealer if service is needed.
G020B01A-AAT Vehicle Exterior The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut
torgue
o Air filter condition
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 (including spare tire)
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6- 22 DO-IT-YOURSELF MAINTENANCE
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
!
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.
!
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.
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