engine Hyundai H-1 (Grand Starex) 2003 Repair Manual

PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
6-8 GASOLINE DIESEL
E VERY
Except E.C EV ERY 3,000 KM
5,000 KM EV ERY 4,000 KM (Except 2.5 CRDi)
or 3 MONTHS EV ERY 7,500 KM or 6 MONTHS (2.5 CRDi only)
MORE FREQUENTLY
MORE FREQUENTLY
EV ERY 60,000 K M or 4 8 MONTHS (Except 2.5 CRDi)
MORE FREQUENTLY
MORE FREQUENTLY
EV ERY 10,000 K M o r 6 MONTHS
MORE FREQUENTLY
EV ERY 100,000 K M
EV ERY 40,000 K M
EV ERY 45 ,000 K M
R R R R
I II
RR R
G070A06P-GAT
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
MAINTENANCE UNDER SEVERE USAGE CONDITIONS MAINTENANCE UNDER SEVERE USAGE CONDITIONS
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
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
ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS TIMING BELT BRAKE PADS, CALIPERS, ROTORSREAR BRAKE DRUMS/LININGSSTEERING GEAR BOX, LINKAGE & BOOTS
AIR FILTER (F o r Evaporator and Blower unit)
MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL A, B, C, F, H C, E B, H D, E, F, G C, D, G, HC, D, G, HC, D, E, FC,EA, C, D, E, F, G, H, I, J A, C, E, F, G, H, I
SEVERE DRIVING CONDITIONS
SEVERE DRIVING CONDITIONS SEVERE DRIVING CONDITIONS
SEVERE DRIVING CONDITIONS
SEVERE DRIVING CONDITIONS
A - Repeated short distance driving
B - Extensive idling
C - Driving in dusty conditions
D - Driving in areas using salt or other corrosive materials or in very cold weatherE - Driving in sandy areas
F - More than 50% driving in heavy city traffic during hot above 32°C (90°F)
G - Driving in mountainous areas
H - Towing a trailer or police car, taxi, or commercial type operation
I - Driving for patrol car, taxi, commercial car or vehicle towing
J - Driving over 170 km/h
For E.C
MAINTENANCE ITEM MAINTENANCE
OPERATION MAINTENANCE
INTERVALS DRIVING
CONDITION
Except E.C For E.C

6-9
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
G080F01P-GAToo
oo
o
Fuel hose, vapor hose and fuel
Fuel hose, vapor hose and fuel Fuel hose, vapor hose and fuel
Fuel hose, vapor hose and fuel
Fuel hose, vapor hose and fuel
filler cap
filler cap filler cap
filler cap
filler cap
The fuel hose, vapor hose and fuel filler cap
should be inspected at those intervals specified in the maintenance schedule. Make sure that anew fuel hose, vapor hose or fuel filler cap iscorrectly replaced. Consult your Hyundai dealerif you have any questions.
G080G01P-GAToo
oo
o Air cleaner filter
Air cleaner filter Air cleaner filter
Air cleaner filter
Air cleaner filter
A genuine Hyundai part is recommended forreplacement of the air cleaner filter. G080H01P-GAT
oo
oo
o Spark plugs
Spark plugs Spark plugs
Spark plugs
Spark plugs
Make sure to install new spark plugs of the correct heat range. G080I01P-GAT
oo
oo
o
Drive belts
Drive belts Drive belts
Drive belts
Drive belts
Inspect all drive belts (water pump and alterna- tor) for evidence of cuts, cracks, excessivewear or oiliness, and replace if necessary.Drive belts should be checked periodically forproper tension and adjusted as necessary.
G080D01P-GAT
oo
oo
o Fuel filter
Fuel filter Fuel filter
Fuel filter
Fuel filter
A clogged filter can limit the speed at which the
vehicle may be driven, damage the emissionsystem and cause hard starting. If an exces-sive amount of foreign matter accumulates inthe fuel tank, the filter may require replacementmore frequently.
After installing a new filter, run the engine for
several minutes, and check for leaks at theconnections.
G080A01P-GAT
EXPLANATION OF SCHEDULED
EXPLANATION OF SCHEDULED EXPLANATION OF SCHEDULED
EXPLANATION OF SCHEDULED
EXPLANATION OF SCHEDULED
MAINTENANCE ITEMS
MAINTENANCE ITEMS MAINTENANCE ITEMS
MAINTENANCE ITEMS
MAINTENANCE ITEMS
oo
oo
o
Engine oil and filter
Engine oil and filter Engine oil and filter
Engine oil and filter
Engine oil and filter
The engine oil and filter should be changed at
those intervals specified in the maintenanceschedule. If the vehicle is being driven in se-vere conditions, more frequent oil and filterchanges are required.
G080B01P-GAT oo
oo
o Valve clearances (DIESEL)
Valve clearances (DIESEL) Valve clearances (DIESEL)
Valve clearances (DIESEL)
Valve clearances (DIESEL)
An incorrect valve clearance will not only result
in rough engine operation, but will also causeexcessive noise and reduced engine output.
Inspect valve clearance and adjust as required
while the engine is hot.
Valve-to-rocker arm clearance:
Valve-to-rocker arm clearance: Valve-to-rocker arm clearance:
Valve-to-rocker arm clearance:
Valve-to-rocker arm clearance: DIESEL:
Hot ............................ 0.25 mm (0.0098 in.) Cold ............................ 0.15 mm (0.0059 in.)
G080C01P-GAT oo
oo
o Fuel lines and connections
Fuel lines and connections Fuel lines and connections
Fuel lines and connections
Fuel lines and connections
Check the fuel lines and connections for leak-
age and damage. Replace any damaged or leaking parts immediately. G080E01P-GAT
oo
oo
o Vacuum and crankcase
Vacuum and crankcase Vacuum and crankcase
Vacuum and crankcase
Vacuum and crankcase
ventilation hoses
ventilation hoses ventilation hoses
ventilation hoses
ventilation hoses
Inspect the surface of hoses for evidence of
heat and/or mechanical damage. Hard andbrittle rubber, cracking, tears, cuts, abrasions,and excessive swelling indicate deterioration.Particular attention should be paid to examiningthose hose surfaces nearest to high heatsources, such as the exhaust manifold.
Inspect the hose routing to assure that the
hoses do not come in contact with any heatsource, sharp edges or moving componentwhich might cause heat damage or mechanicalwear. Inspect all hose connections, such asclamps and couplings, to make sure they aresecure, and that no leaks are present. Hosesshould be replaced immediately if there is anyevidence of deterioration or damage.

PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
6-10 G080N01P-GAT
oo
oo
o Brake hoses and lines
Brake hoses and lines Brake hoses and lines
Brake hoses and lines
Brake hoses and lines
Visually check for proper installation, chafing, cracks, deterioration and any leakage. Replaceany deteriorated or damaged parts immedi-ately. G080O01P-GAT
oo
oo
o Brake fluid
Brake fluid Brake fluid
Brake fluid
Brake fluid
Check brake fluid level in the brake fluid reser- voir. The level should be between "MIN" and"MAX" marks on the side of the reservoir. Useonly hydraulic brake fluid conforming SAEJ1703. G080P01P-GAT
oo
oo
o Rear brake drums and linings
Rear brake drums and linings Rear brake drums and linings
Rear brake drums and linings
Rear brake drums and linings
Check for scoring, burning, leaking fluid, bro- ken parts, and excessive wear. G080Q01P-GAT
oo
oo
o Brake pads, calipers and rotors
Brake pads, calipers and rotors Brake pads, calipers and rotors
Brake pads, calipers and rotors
Brake pads, calipers and rotors
Check the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage. G080R01P-GAT
oo
oo
o
Parking brake
Parking brake Parking brake
Parking brake
Parking brake
Inspect the parking brake system such as parking brake lever, cables, and so on. Fordetailed service procedures, refer to the ShopManual. G080S01P-GAT
oo
oo
o
Exhaust pipe connections,
Exhaust pipe connections, Exhaust pipe connections,
Exhaust pipe connections,
Exhaust pipe connections,
muffler and suspension bolts
muffler and suspension bolts muffler and suspension bolts
muffler and suspension bolts
muffler and suspension bolts
Check the exhaust pipe, muffler, and suspen-sion connections for looseness or damage. G080T01P-GAT
oo
oo
o
Steering gear box, linkage and boots
Steering gear box, linkage and boots Steering gear box, linkage and boots
Steering gear box, linkage and boots
Steering gear box, linkage and boots
With the vehicle stopped and engine off, check for excessive free-play in the steering wheel.Check the linkage for bends or damage. Checkthe dust boots and ball joints for deterioration,cracks, or damage. Replace any damaged parts. G080U01P-GAT
oo
oo
o Wheel bearing grease
Wheel bearing grease Wheel bearing grease
Wheel bearing grease
Wheel bearing grease
Check the wheel bearings and grease accord- ing to the maintenance schedule. For inspec-tion procedures, see Shop Manual.
G080J01P-GAT
oo
oo
o Engine coolant
Engine coolant Engine coolant
Engine coolant
Engine coolant
The coolant should be changed at those inter-
vals specified in the Vehicle Maintenance Re-quirements Section.
G080K01P-GAT oo
oo
o
Timing belt
Timing belt Timing belt
Timing belt
Timing belt
Inspect all parts related with the timing belt for
damage and deformation. Replace any dam-aged parts.
G080L01P-GAT oo
oo
o Manual transmission oil
Manual transmission oil Manual transmission oil
Manual transmission oil
Manual transmission oil
Check manual transaxle oil according to the
maintenance schedule.
NOTE:
NOTE: NOTE:
NOTE:
NOTE:
If the oil level is low, check for possible
If the oil level is low, check for possible If the oil level is low, check for possible
If the oil level is low, check for possible
If the oil level is low, check for possible leaks before adding oil. Do not overfill.
leaks before adding oil. Do not overfill. leaks before adding oil. Do not overfill.
leaks before adding oil. Do not overfill.
leaks before adding oil. Do not overfill.
G080M02P-GAT oo
oo
o
Automatic transmission fluid
Automatic transmission fluid Automatic transmission fluid
Automatic transmission fluid
Automatic transmission fluid
The fluid level should be in the "HOT" range of
the dipstick, after engine and transaxle are at normal operating temperature. Check the Auto-matic Transaxle Fluid level with the enginerunning and the transaxle in neutral, with theparking brake properly applied. Use GENUINEHYUNDAI ATF AUTOMATIC TRANSMISSIONFLUID, DIAMOND ATF DEXRON II or DIA-
MOND ATF SP I when adding or changing
fluid.

7-1
EMISSION CONTROL SYSTEM
EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM
EMISSION CONTROL SYSTEM
EMISSION CONTROL SYSTEM
H030A01P-GAT2.2.
2.2.
2.
EE
EE
E
VAPORATIVE
VAPORATIVE VAPORATIVE
VAPORATIVE
VAPORATIVE E
E E
E
E MISSION CON-
MISSION CON- MISSION CON-
MISSION CON-
MISSION CON-
TROL
TROL TROL
TROL
TROL SS
SS
S YSTEM
YSTEM YSTEM
YSTEM
YSTEM (
( (
(
( EE
EE
E xcept canister)
xcept canister) xcept canister)
xcept canister)
xcept canister)
The Evaporative Emission Control System is
designed to prevent fuel vapors from escaping into the atmosphere.
If the fuel-vapor vent line is clogged or dam-
aged, the fuel-vapor mixture will escape intothe atmosphere and cause insufficient emis-sion control. Disconnect the line at both ends, and blow it
clean with compressed air.
Remove the filler cap from the filler pipe, and
check to see if there is evidence that thepacking contact to the filler pipe is faulty. Theoverfill limiter (2-way valve) installed on thevapor line between the canister inlet and fueltank outlet must be checked for correct opera-tion. H050A01P-GAT
3.3.
3.3.
3.
EXHAUST EMISSION CONTROL
EXHAUST EMISSION CONTROL EXHAUST EMISSION CONTROL
EXHAUST EMISSION CONTROL
EXHAUST EMISSION CONTROL
SYSTEM
SYSTEM SYSTEM
SYSTEM
SYSTEM
The Exhaust Emission Control System is a
highly effective system which controls exhaustemission while maintaining good vehicle per-formance.
H060A01P-GATCC
CC
C
atalytic Converter
atalytic Converter atalytic Converter
atalytic Converter
atalytic Converter
All Hyundai vehicles are equipped with a mono-
lith type three-way catalytic converter to re-duce the carbon monoxide, hydrocarbons andnitrogen oxides contained in the exhaust gas.
H000A01P-GAT
7.7.
7.7.
7.
EMISSION CON-
EMISSION CON- EMISSION CON-
EMISSION CON-
EMISSION CON-
TROL SYSTEM
TROL SYSTEM TROL SYSTEM
TROL SYSTEM
TROL SYSTEM
H010A01P-GAT EMISSION CONTROL SYSTEM
EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM
EMISSION CONTROL SYSTEM
EMISSION CONTROL SYSTEM
(Gasoline)
(Gasoline) (Gasoline)
(Gasoline)
(Gasoline) Your Hyundai is equipped with an emission
control system. There are three emission control systems which
are as follows.
(1) Crankcase emission control system (2) Evaporative emission control system(3) Exhaust emission control system In order to assure the proper function of the
emission control systems, it is recommended that you have your vehicle inspected and main-tained by an authorized Hyundai dealer in ac-cordance with the maintenance schedule inthis manual.
H020A01P-GAT1.1.
1.1.
1.
CRANKCASE EMISSION CONTROL
CRANKCASE EMISSION CONTROL CRANKCASE EMISSION CONTROL
CRANKCASE EMISSION CONTROL
CRANKCASE EMISSION CONTROL
SYSTEM
SYSTEM SYSTEM
SYSTEM
SYSTEM
The positive crankcase ventilation system is
employed to prevent air pollution caused byblow-by gases being emitted from the crank-case. This system supplies fresh air to thecrankcase through the air cleaner. Inside thecrankcase, the fresh air mixes with blow-bygases, then passes through the PCV valve intothe induction system. H080A01P-GAT
PCV Valve
PCV Valve PCV Valve
PCV Valve
PCV Valve
The crankcase ventilation system must be kept
clean to maintain good engine performance.
Periodic servicing is required to remove com-
bustion products from the PCV valve. H040A01P-GAT
Canister
Canister Canister
Canister
Canister While the engine is inoperative, fuel vapors
generated inside the fuel tank are absorbed and stored in the canister. When the engine isrunning, the fuel vapors absorbed in the canis-ter are drawn into the induction system throughthe purge control solenoid valve.
H090A01P-GATPurge Control Solenoid Valve
Purge Control Solenoid Valve Purge Control Solenoid Valve
Purge Control Solenoid Valve
Purge Control Solenoid Valve
The purge control solenoid valve is controlled
by the ECU; when the engine coolant tempera-ture is low, and during idling, it closes, so thatevaporated fuel is not taken into the surge tank.After engine warm-up, during ordinary driving, it opens so as to introduce evaporated fuel to the surge tank.
77
77
7

8-1
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
1. Windshield washer fluid reservoir cap
2. Engine oil filler cap
3. Engine oil level dipstick
4. Brake booster 5. Brake fluid reservoir
6. Engine coolant reservoir
7. Radiator cap
8. Air cleaner 9. Power steering fluid reservoir
10. Battery
I000A01P-GAT
8.8.
8.8.
8.
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
I010A01P-GAT DIESEL E
DIESEL E DIESEL E
DIESEL E
DIESEL E NGINE
NGINE NGINE
NGINE
NGINE R R
R R
R
OOM (F
OOM (F OOM (F
OOM (F
OOM (F
or 2.6 N/A)
or 2.6 N/A) or 2.6 N/A)
or 2.6 N/A)
or 2.6 N/A)
I010A01P-1
123
45 67
10
9
8
88
88
8

CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
8-2
I010D01P
12 345 67
10
9
8
1. Windshield washer fluid reservoir cap
2. Engine oil filler cap
3. Engine oil level dipstick
4. Brake booster 5. Brake fluid reservoir
6. Engine coolant reservoir
7. Radiator cap
8. Air cleaner 9. Power steering fluid reservoir
10. Battery
1 1 . Fuse and relay box
I010D01P-GAT
DIESEL ENGINE ROOM (For 2.5 4D56 T/C)
DIESEL ENGINE ROOM (For 2.5 4D56 T/C) DIESEL ENGINE ROOM (For 2.5 4D56 T/C)
DIESEL ENGINE ROOM (For 2.5 4D56 T/C)
DIESEL ENGINE ROOM (For 2.5 4D56 T/C)
11

8-3
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
I010B01P
1. Windshield washer fluid reservoir cap
2. Automatic transmission fluid level dipstick (A/T only)
3. Engine oil filler cap
4. Engine oil level dipstick 5. Brake booster
6. Brake fluid reservoir
7. Engine coolant reservoir
8. Air cleaner
9. Power steering fluid reservoir
10. Battery
1 1 . Fuse and relay box
12
3 456 7
8 91
011
I010B01P-GAT
DIESEL ENGINE ROOM (For 2.5 4D56 TCI)
DIESEL ENGINE ROOM (For 2.5 4D56 TCI) DIESEL ENGINE ROOM (For 2.5 4D56 TCI)
DIESEL ENGINE ROOM (For 2.5 4D56 TCI)
DIESEL ENGINE ROOM (For 2.5 4D56 TCI)

CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
8-4
I010C01P
1. Windshield washer fluid reservoir cap
2. Engine oil filler cap
3. Brake booster 4. Brake fluid reservoir
5. Engine coolant reservoir
6. Air cleaner
12
34 5
6 79
10
I010C01P-GAT
DIESEL ENGINE ROOM (For 2.5 CRDi TCI)
DIESEL ENGINE ROOM (For 2.5 CRDi TCI) DIESEL ENGINE ROOM (For 2.5 CRDi TCI)
DIESEL ENGINE ROOM (For 2.5 CRDi TCI)
DIESEL ENGINE ROOM (For 2.5 CRDi TCI)
8
7. Power steering fluid reservoir
8. Engine oil level dipstick
9. Battery
1 0 . Fuse and relay box

8-5
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
1. Washer tank cap
2. Engine oil filler cap
3. Engine oil level gauge
4. Brake booster 5. Brake fluid reservoir
6. Radiator cap
7. Air cleaner
8. Power steering oil tank
9. Battery
10. Fuse box
123456
78910
I011A01P-2
I011A02P-GAT
GASOLINE ENGINE ROOM
GASOLINE ENGINE ROOM GASOLINE ENGINE ROOM
GASOLINE ENGINE ROOM
GASOLINE ENGINE ROOM

CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
8-6 I040A01P-GAT
Vehicle Interior
Vehicle Interior Vehicle Interior
Vehicle Interior
Vehicle Interior
The following should be checked each time when the vehicle is driven:
o Light operation
o Windshield wiper operation
o Horn operation
o Defroster, heater operation (and air condi- tioning, if equipped)
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 transmission operation, including clutch operation
o Automatic transmission operation, including "Park" mechanism operation
o Seat control condition and operation
o Seat belt condition and operation
o Sunvisor operation
If you notice anything that does not operate correctly or appear to be functioning correctly,inspect it carefully and seek assistance fromyour Hyundai dealer if service is needed. Adequate care of your vehicle at regular inter- vals serves to preserve the value and appear-ance as long as possible. Some maintenance items can be carried out bythe owner (Consumer Information), while othershould be done only by an authorized dealer(Periodic Inspection and Maintenance). Thissection describes only those items which canbe carried out by the owner. In the event amalfunction or other problem is discovered,have it corrected by an authorized HYUNDAIdealer. This section contains information oninspection maintenance procedures that youcan do yourself, if you so desire. Follow theinstructions and cautions for each of the vari-ous procedures. When checking or servicing the inside of the engine compartment, be sure the engine isstopped and has had a chance to cool down. Ifit is necessary to do work in the engine com-partment with the engine running, be especiallycareful that your clothing, hair, etc., becomesnot caught by the fan, V-belts, or other movingparts. I050A01P-GAT
Inspection items
Inspection items Inspection items
Inspection items
Inspection items
( 1 ) Engine oil
( 2 ) Engine coolant
(3) Battery
( 4 ) Brake fluid
( 5 ) Clutch fluid (hydraulic clutch only)
( 6 ) Washer fluid
( 7 ) Wheel condition (including spare wheel)
(8) Tire inflation pressure (including spare
wheel)
I020A02P-GAT
GENERAL CHECKS
GENERAL CHECKS GENERAL CHECKS
GENERAL CHECKS
GENERAL CHECKS
Engine Compartment
Engine Compartment Engine Compartment
Engine Compartment
Engine Compartment The following should be checked regularly:
o Engine oil level and condition
o Transmission 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 Coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level and condition
o Tire pressure and condition (including spare)
o Battery condition I030A02P-GAT
Vehicle Exterior
Vehicle Exterior Vehicle Exterior
Vehicle Exterior
Vehicle Exterior The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut tightness
o Air cleaner filter condition
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and corrosion
o Fluid leaks
o Door and hood lock condition