lock Hyundai Getz 2005 Workshop Manual

VEHICLE MAINTENANCE REQUIREMENTS 5- 5
F030C02TB-EAT R : Replace I : Inspect and, after inspection, clean, adjust, repairer or replace if necessary
GENERAL MAINTENANCE COOLING SYSTEMCOOLANTCOOLANT SPECIFIC GRAVITYMANUAL TRANSAXLE OILAUTOMATIC TRANSAXLE FLUIDBRAKE PIPES, HOSES, AND CONNECTIONSBRAKE FLUIDCLUTCH FLUIDREAR BRAKE LININGS AND CYLINDERSBRAKE PADSSUSPENSION AND STEERING SYSTEMFRONT SUSPENSION BALL JOINTSPOLLEN FILTER (FOR EVAPORATOR AND BLOWER UNIT)REAR WHEEL BEARINGSTYRE CONDITION AND PRESSURE (incl. Spare)LUBRICATE LOCKS AND HINGESCHECK ALL ELECTRICAL SYSTEMSROAD TESTCHECK ALL SYSTEMS WITH HI-SCAN
60 72
5060
4048
I I I
R
I
RR II I I
R III I II
I I I IIIII I II
R II I III
I I I II
RR I I II
R II I III
30 36
2024
I I I IIIII I II
R II I III
I I I II
RR I I II
R II I III
10 12
I I I IIIII I II
R II I III
MILES X 1000MONTHS
NO. DESCRIPTION
1 23456789
10111213141516171819
See NOTE (1)
Note :(1) FOR THE FIRST TIME, REPLACE THE COOLANT 60,000 MILES OR 60 MONTHS. AFTER THAT, REPLACE IT EVERY 30,000 MILES OR 24 MONTHS.

6- 8 DO-IT-YOURSELF MAINTENANCE
Petrol engine
HTB169
HTB169A
Diesel engine
G030D01TB-EAT ENGINE OIL REPLENISHMENT
If the indicated oil level is at or below the lower mark of the dipstick, oil should be added until the level is at or below the upper mark.To add oil to the engine, remove the filler cap by rotating in an counterclock- wise direction and pour engine oil intothe engine. Before checking the level again, allow several minutes for the oil to drain into the sump. Replace the oilfiller cap rotating it in a clockwise direc- tion until tight. The quantity of oil required to raise thelevel from the minimum to maximum level is approximately 1.2 litre.ZG030E1-E ENGINE OIL CONSUMPTION Function of engine oil Engine oil has the primary function of lubricating and cooling the inside of the engine. Engine oil consumption It is normal that an engine should con- sume some engine oil while normal driving. The cause of oil consumption in a normal engine are as follows;
o Engine oil is used to lubricate pis-
tons, piston rings and cylinders. A thin film of oil is left on the cylinder wall when a piston moves down- wards in the cylinder. High negativepressure generated during engine operation sucks some of the oil into the combustion chamber.This oil with some oil of the cylinder wall is burned by the high tempera- ture combustion gases during thecombustion process.
o The engine oil consumption is strongly
effected by the viscosity and qualityof oil, engine rpm and driving condi- tion etc.

6- 10 DO-IT-YOURSELF MAINTENANCE
!
!
HTB170
Petrol engine SG050A1-E ENGINE COOLANT CHECKING AND REPLACING
SG050B1-E Coolant recommendations WARNING:
Do not remove the radiator cap when the engine is hot, since the system is pressurized and coolant may be ejected from the radiator resulting inscalding.
3. Prepare a suitable receptacle to col-
lect the displaced oil and remove thedrain plug from the sump.
4. When the oil has drained from the sump, replace the drain plug using anew washer ensuring that the plug is not over tightened. Tightening torque is: 3.5 ~ 4.5 kgf.m
5. Remove the oil filter by rotating coun- terclockwise, using a proprietary oil filter removal tool if necessary. Notethat the oil filter will contain approxi- mately 0.5 litres of oil and this should be collected in a suitable receptacle.
6. Install a new oil filter having smeared the sealing ring with clean oil androtating clockwise until the filter con-tacts the mounting and then a further one half turn. Do not over-tighten CAUTION:
The oil being drained from the en- gine will be hot. Care should beexercised to prevent scalding.
! Tightening torque: Petrol -
1.2 ~ 1.6 kgf.m
Diesel(RHD) - 2.3 ~ 2.5 kgf.m
7. Pour the specified quantity of the recommended oil into the engine and replace the filler cap. Start the en- gine and ensure that no oil leaks exist. Turn off the engine and after acouple minutes, recheck the oil level.
WARNING:
Prolonged and repeated contact with used engine oils may result in seri- ous skin disorders including derma- titis and cancer. Avoid contact with skin as far as possible and alwayswash thoroughly after any contact. Keep used oils out of reach of chil- dren. It is illegal to pollute drains,water courses and soil. Use only authorized waste collection facili- ties including civic amenity sitesand garages for the disposal of used oil and oil filters. If in doubt, contact the local authority for disposal in-structions.

DO-IT-YOURSELF MAINTENANCE 6- 13
SG060A1-E SPARKING PLUG REPLACE- MENT
G060A01L
0.039 ~ 0.043 in. (1.0 ~ 1.1 mm )
This operation should only be performed when the engine is cold.
1. Remove the centre cover from the engine rocker cover.
2. Remove plug lead from the sparking plug to be replaced, pulling the lead by the rubber cap. (Pulling the lead may damage the carbon conductor).
3. Clean around the base of the plug to be removed, and install the plugsocket ensuring that the ceramicinsulator does not become damaged. Turn the socket counterclockwise to remove the plug. CAUTION:
Sparking plugs must only be cleaned using purpose designed equipment. Wire brushing may damage the cen-tre electrode-insulator causing mis- firing to occur. Only the correct grade of sparking plug should be used.Use of an incorrect grade may result in serious engine damage. Prior to installing a sparking plug, the gap between the centre and outer elec- trodes must be checked and adjusted as necessary. Adjustment is facilitated by bending the outer electrode towards or away fromthe centre electrode. Under no circum- stances should attempts be made to adjust the position of the centre elec-trode.
4. Insert the sparking plug into the cyl- inder head and screw by the wrench and until the plug contacts the seat- ing area. Tighten the plug with the socket by a further 1/2 to 3/4 of a turnonly. 5. Replace the plug lead ensuring that
the cap is pushed firmly into place.Confirm that the cap is correctlyseated by lightly pulling upon it.
NOTE: When replacing the spark plug, al- ways use the genuine parts recom- mended. Recommended Spark Plugs
CHAMPION NGKRC10YC4 BKR5ES-11
!

DO-IT-YOURSELF MAINTENANCE 6- 19
!WARNING:
Brake fluid is hygroscopic and should never be stored in an un- sealed container. The presence ofwater in the braking system will cause vapour locks and increase the possi- bility of brake fade along with pro-moting corrosion within the braking system. The brake fluid must be changed at the specified time or mile-age interval to ensure continued safe operation of the system. Brake fluid will cause rapid and serious damageto paintwork. If accidental spillage occurs, the affected area must be rinsed with water immediately. Donot allow brake fluid to come into SG140A1-E AIR CONDITIONING SYSTEM MAINTENANCECondenser Ensure that the condenser is periodi- cally inspected and that accumulationsof dirt, dead insects and leaves etc, are removed to ensure that the efficiency of the system is not impaired. Care mustbe exercised to ensure that the con- denser fins are not damaged during cleaning.
G140D01TB-EAT Compressor Drive BeltG140D01TB
Power steering
Crank pully
A/C pully
0.19 ~ 0.21 in. (5 ~ 5.5 mm)
1.1L
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. contact with the eyes or to be in-gested and ensure that fluid is safelystored away form the reach of chil- dren.
CRANK PULLEY
HTB219
A/C
TENSION PULLEY 0.315 in. (8mm)
1.3/1.6L

DO-IT-YOURSELF MAINTENANCE 6- 35
G200E01TB-GAT Inner Panel
HTB260-DFUSE RATING10A 10A10A10A10A10A 10A 15A10A10A20A15A 10A 20A10A15A15A15A 20A 10A10A10A30A15A 10A 15A15APROTECTED COMPONENTS
Air conditioner
Stop/Tail Light (LH) A/Bag IndicatorAudio, Electronic Outside Mirror
Turn signal Light, Back-up Light
Stop/Tail Light (RH)Cluster Cigarette Lighter PCM, ABS controlAir BagDoor Lock System, SunroofRear Wiper Motor
Start Relay, 9oTheft alarm system Seat Warmer Rear window DefrosterECM
Stop Light, Power Window
Hazard Warning Light, ETACMFront Wiper Motor Rear Fog Light
Fog light, ETACM, Power Window, Headlight leveling Device
Blower, SunroofRear window DefrosterHeadlight (RH)Front Fog Light
High Beam Light Indicator, Headlight (LH) Room Lamp, Audio, Cluster
DESCRIPTION
A/C SW
TAIL LH
A/BAG IND
AUDIO
T/SIG
TAIL RH
CLUSTER C/LIGHT ECU 1
A/BAG
D/LOCK
RR/WPR STARTS/HTD
HTD MIR ECU2
STOP
HAZARD
FRT WPR R/FOG
IGNITION BLOWER PR/HTD
H/LP RH F/FOG
H/LP LH
POWER CONN & R/LP

EMISSION CONTROL SYSTEMS 7- 3
H020A01TB-EAT
CATALYTIC CONVERTOR OP- ERATION PRECAUTIONS ; For a Petrol engine
Hyundai Getz models are fitted with
catalytic convertors which require special operating considerations. Thecatalytic convertor serves to oxidize certain noxious elements of the ex- haust gases leaving the engine toreduce the level of pollutants emitted from the vehicle and, provided that care is exercised to prevent damage,the catalyst will operate efficiently for the life of the vehicle.
It is of the utmost importance that the
following information is read and un-derstood by the vehicle operator in
HTB178Catalytic Converter order to prevent operational problems arising from damage to the catalyst.
Damage to the catalyst will result if
contamination occurs through the use of leaded fuel. Whilst the vehicle isfitted with a reduced diameter filler neck to prevent charging of the fuel tank with a leaded fuel pump nozzle,it is possible that the use of funnels or jerry cans will permit leaded fuel to be introduced into the fuel tank.
The catalyst is intolerant of unburnt
fuel and therefore if an engine misfirecondition exists, damage to the cata-lyst will occur. It is imperative that if a misfire condition develops, the ve- hicle is immediately presented to aHyundai dealer for rectification. Simi- larly, the practice of certain ignition system diagnosis procedures whichinvolve inducing a misfire (cylinder power balance tests for example) may result in catalyst damage.
For these reasons, it is advisable that
the exhaust gas emission be testedat each routine service with a gas analyzer having a Hydrocarbon mea- suring facility to ensure continuedreliability of the catalyst. Push or tow starting of the vehicle is to be avoided since unburnt fuel may be enter the catalyst and result indamage. (Note, it is impossible to push or tow start a Hyundai model equipped with fuel injection since thefuel pump safety interlock will prevent the pump from operating under these conditions).Operation of the catalyst involvesextremely high temperatures beingattained within the catalytic conver- tor, and although the convertor is fitted with heat shields, it is importantthat the vehicle is not parked over combustible or volatile material which may result in fire. If the above precautions are not ad- hered to and the catalyst becomes inoperative, the resultant increase incore temperature will result in a "melt down" where the catalyst core will melt and subsequently may block theexhaust system.Due to the fragile nature of the cata-lyst element, it is important that dam- age does not occur when the vehicle is raised by means of a garage jack.Care must also be exercised to avoid driving over road hazards or debris which may cause damage to the cata-lyst element.

CONSUMER INFORMATION 8- 3
4.5Jx13 5.0Jx13 5.0Jx14 5.5Jx145.5Jx15
4.0Tx14 TYRE
SIZE
RIM
SIZE PRESSURE, kPa (PSI)
15/80R13
165/65R14175/65R14185/55R15
T105/70D14 REAR
210(30) 420(60) FRONT
230(33) 420(60)
UP TO 2
PERSONS UP TO
MAX. LOAD
REAR
230(33)420(60)
FRONT 210(30) 420(60)
The engine number is stamped on the engine block as shown in the drawing. I030A02TB-EAT TYRE PRESSURES In modern high-speed motoring, correct tyre pressures are vitally important.
I010B01B
HTB263
Diesel EngineIncorrect tyre pressures can affect ve- hicle safety by causing reduced adhe- sion, steering response and tyre failurethrough overheating. The tyre pressure must only be checked when the tyres are cold. The correct tyre pressures areindicated on the label affixed in the glove box and below. Tyre pressures should be increased by 3 psi when the vehicle is driven fully laden or under conditions of sustained high speed motoring.

10- 2 INDEX
A AIR BAG ................................................................... 1-30
AIR CONDITIONING SWITCH .................................1-74
AIR CONDITIONING SYSTEM MAINTENANCE ..... 6-19
AIR CLEANER FILTER ............................................. 6-14
ANTENNA ................................................................. 1-84
ANTI-LOCK BRAKE SYSTEM .................................. 2-13
ANTI-THEFT ALARM SYSTEM .................................. 1-7
ASHTRAY ................................................................. 1-54
AUTO FUEL CUT SW ITCH...................................... 1-68
AUTOMATIC TRANSAXLE ......................................... 2-9AUTOMATIC TRANSAXLE FLUID ...........................6-16
BBATTERY MAINTENANCE ......................................6-25
BEFORE STARTING THE ENGINE ...........................2-3
BONNET RE LEASE.................................................. 1-62
BRAKE PEDAL FREEPLAY .....................................6-22
BRAKE SYSTEM CHECKING ..................................6-18
CCARE OF DISC ......................................................... 1-82
CARE OF SEAT BELTS .... .......................................1-19
CARGO AREA COVER ............................................ 1-66
CATALYTIC CONVERTOR OPERATING PRECAUTIONS ...................................................... 7-3
CENTRAL DOOR LOCKS .......................................... 1-5
CHANGING A FLAT TYRE ......................................... 3-6 CHILD-PROOF REAR DOOR
LOCK .......................... 1-5
CHILD RESTRAINT SYSTEM ..................................1-22
CIGAR LIGHTER ...................................................... 1-53
CLUTCH PEDAL FR EEPLAY................................... 6-22
COMBINATION IGNITION SWITCH AND STEERING LOCK ................................................... 2-3
CONSOLE TRAY ...................................................... 1-54
COOLANT TEMPERATURE GAUGE .......................1-44
DDAILY OPERATING CHECKS .................................... 6-6
DIGITAL CLOCK ....................................................... 1-53
DOOR LOCK S ............................................................ 1-5
DOOR WINDOWS .................................................... 1-10
DRINK HOLDER ....................................................... 1-54
DRIVE BELTS ........................................................... 6-23
DRIVING FOR ECONOMY .......................................2-14
EEFFECTIVE BRA KING............................................. 2-13
ELECTRIC COOLING FANS ....................................6-25
EMERGENCY TOWING .... .......................................3-12
EMISSION CONTROL SYSTEM ................................ 7-2
ENGINE COMPARTMENT .................... ..................... 6-2
ENGINE COOLANT CHECKING AND REPLACING ......................................................... 6-10
ENGINE OIL AND FILTER REPLACEMENT .............. 6-9
ENGINE OIL CONSUMPTION ................................... 6-8

INDEX 10- 5
SUPPLEMENTAL RESTRAINT (AIRBAG)
SYSTEM ............................................................... 1-30
STARTING THE ENGI NE ........................................... 2-5
STEERING WHEEL FREEPLAY ..............................6-21
STEERING WHEEL LOCK ......................................... 2-4 STEERING WHEEL TILT LEVER ............................. 1-69
STEREO SOUND SYSTEM ......................................1-80
SUN-VISOR .............................................................. 1-69
SUNROOF ................................................................ 1-55
TTACHOMETER ......................................................... 1-45
TAIL GATE ................................................................ 1-64
TOWING ATTACHMENTS ................. ...................... 2-17
TRAILER AND CARAVAN TOWING ........................2-17
TRIP ODOMETER .................................................... 1-45
TRIP COMPUTER .................................................... 1-46
TYPE PRESSURES .................................................... 8-3
TYRE BALANCING ..................................................... 8-5
TYRE CHAINS ............................................................ 8-4
TYRE REPLACEMENT ............................................... 8-5
TYRE ROTATION ....................................................... 8-4
U
UNDERBODY COATINGS ......................................... 4-2 V VALETING
.................................................................. 4-3
VEHICLE IDENTIFICATION NUMBER ....................... 8-2
VEHICLE SPECIFICATION ........................................ 9-2 VEHICLE TOWING OR RECOVERY ....................... 3-11
VENTILATION .......................................................... 1-71
W
WHEEL REPLACEMENT ..... ...................................... 8-5
WINDSCREEN WASHER RESERVOIR REPLENISHMENT ................................................ 6-15
WINDSCREEN WIPER BLADES ..............................6-14
WINDSHIELD WIPER/WASHER SWITCH ...............1-50
WINTER MOTORING ............................................... 2-15