engine coolant Hyundai H-1 (Grand Starex) 2004 Owner's Manual

1BEFORE DRIVING YOUR VEHICLE
2RUNNING-IN RECOMMEN- DATIONSBEFORE DRIVING YOUR VEHICLE SAFETY CHECKS
Drive range1st
2nd 3rd
4th 5th
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B010A01P-GAT Be sure you know your vehicle and its equipment and how to use it safely. B010B01P-GAT Before entering the vehicle
o Check that windows, mirrors and lights are clean.
o Check if any tire is low or flat.
o Look for fluid leaks.
o Check that area is clear if you're about to back up.
B010C03P-GAT After entering the vehicle
o Lock all doors.
o The driver and passengers are wear- ing properly adjusted seat belts.
o The head restraints are properly adjusted, if so equipped.
o Adjust inside and outside mirrors.
o Check warning lights for correct
operation, with the ignition key in the position "ON".
o Check all gauges, for normal opera- tion. WARNING: (Diesel only)
To ensure that sufficient vacuum exists within the brake system dur-ing cold weather start-up condi- tions, it is necessary to run the engine at idle after starting the en-gine. NOTE: Fluid levels, such as engine oil, engine coolant, brake fluid, and windshield washer fluid, should be checked daily and/or weekly, orwhenever you refuel. Further details are described in the "CONSUMER INFORMATION" sec-tion. B020A01P-GAT During the running-in period for the first 1,000km(600miles), it is advisable to drive your new vehicle using the following precautions as a guideline toaid long life as well as future economy and performance.
1. Do not race the engine at high
speeds.
2. Avoid rapid starting, acceleration,
braking and prolonged high-speedrunning.
3. Keep to the running-in speed limit
shown below.
Please note that the legal speed limitsdisplayed must be adhered to.
4. Do not exceed loading limits.
5. Refrain from towing a trailer.
km/h (mph)
Running-in speed 0~25(0~16)
20~50(13~31) 30~80(19~50)
40~(25~) 50~(32~)

2 INSTRUMENTS AND CONTROLS
12INSTRUMENT CLUSTER
B290A02A-AAT ENGINE COOLANT TEMPERATURE GAUGE Minibus/Van
C080A01P-GAT FUEL GAUGE Minibus/Van
The fuel gauge indicates the fuel level in the fuel tank regardless of the igni- tion switch position.
With Tachometer
Without Tachometer C080A02P
C080B02P With Tachometer
C090A02P
C090B02P
Without Tachometer
Truck
C080C02P

2
INSTRUMENTS AND CONTROLS
13
C090C02P
!WARNING:
Never remove the radiator cap when the engine is hot. The engine cool- ant is under pressure and could erupt and cause severe burns. Waituntil the engine is cool before re- moving the radiator cap. The needle on the engine coolant tem- perature gauge should stay in the nor-mal range. If it moves across the dial to "H" (Hot), pull over and stop as soon as possible and turn off the engine. Thenopen the hood and after the engine has cooled, check the coolant level and the water pump drive belt. If you suspectcooling system trouble, have your cool- ing system checked by a Hyundai dealer as soon as possible. C040A02P-GAT SPEEDOMETER Minibus/Van
The speedometer indicates the vehicle's speed in kilometers per hour(km/h) or miles per hour (mph).
C040A02P C040A01P-1
Truck
Truck

3 STARTING AND OPERATING
28WINTER DRIVING
D180A01P-GAT Engine oil The engine oil can become very thick at low temperatures, thus making itdifficult to start the engine. Change to a thinner oil designed for winter use before the start of coldweather; for the appropriate oil viscos- ity, refer to the "Consumer Informa- tion" section. D180B01P-GAT Engine coolant If the temperature in your area drops below freezing, there is the danger thatthe coolant in the engine or radiator could freeze and cause severe dam- age to the engine and/or radiator.Be sure to add a sufficient amount of antifreeze to the coolant to prevent it from freezing.The engine coolant mixture used at the factory is intended to be left in the cooling system and provides protec-tion against freezing for temperature as low as approximately -30°C (-20°F). The concentration should be checkedbefore the start of cold weather and anti-freeze added to the system if nec- essary.SMOOTH CORNERING
C150A01A-AAT Avoid braking or gear changing in cor- ners, especially when roads are wet. Ideally, corners should always be taken under gentle acceleration. If you followthese suggestions, tire wear will be held to a minimum.

44IN CASE OF EMERGENCY
14
C190B01S-AAT Trailer Hitches Select the proper hitch and ball combi- nation, making sure that its location iscompatible with that of the trailer or vehicle being towed. Use a quality non-equalizing hitch which distributesthe tongue load uniformly throughout the chassis. The hitch should be bolted securely to the car and installed by a qualified technician. DO NOT USE A HITCHDESIGNED FOR TEMPORARY IN- STALLATION AND NEVER USE ONE THAT ATTACHES ONLY TO THEBUMPER.C190C01P-GAT Trailer Brakes If your trailer is equipped with a braking system, make sure it conforms to fed-eral and/or local regulations and that it is properly installed and operating cor- rectly. NOTE: If you tow a trailer or vehicle, your car will require more frequent main-tenance due to the additional load. See "Maintenance Under Severe Usage Conditions" on page 6-11.
CAUTION:
o Never connect a trailer brake sys- tem directly to the vehicle brakesystem.
o When towing a trailer on steep
grades (in excess of 12%) payclose attention to the engine cool- ant temperature gauge to ensure the engine does not overheat. Ifthe needle of the coolant tem- perature gauge moves across the dial towards "H" (HOT), pull over
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C190A01A-GAT TRAILER OR VEHICLE TOWING If you are considering towing with your car, you should first check with yourProvince Department of Motor Vehicles to determine their legal requirements. Since laws vary from province to prov-ince, the requirements for towing trail- ers, cars, other types of vehicles, or apparatus may differ. Ask your Hyundaidealer for further details before towing.
CAUTION:
Do not do any towing with your carduring its first 2,000 km (1,200 miles)in order to allow the engine to prop- erly break in. Failure to heed this caution may result in serious en-gine or transmission damage.
!

44IN CASE OF EMERGENCY
22IF THE ENGINE OVERHEATS
CAUTION:
o Do not allow the jumper cable clips to touch one another.
o Do not connect the jumper cable
to the negative terminal of the flat battery. The battery generates explosive gas, and a spark caused whenthe jumper cable is disconnected from the negative terminal could ignite this gas and cause an ex-plosion.
o Be careful that the jumper cable
becomes not caught in the cool-ing fan, etc.
! D030A02A-AAT If your temperature gauge indicates overheating, you experience a loss of power, or hear loud pinging or knock- ing and the engine is probably too hot.If this 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 transmission), or neutral (manual transmission) and set the parking brake. If the air conditioning is on, turn it off.
3. If engine coolant is running out un- der the car or steam is coming outfrom 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.
the other end to the engine block of the vehicle with the flat batteryat the point farthest from the battery.
8. Start engine as described "Starting the engine" in section 3.
9. After the engine is started, discon- nect the cables in the reverse order.
1. Both batteries must be 12V. The
capacity (Ah) of the battery supply- ing current should not be signifi- cantly below that of the discharged battery.
2. Use only heavy-duty jumper cables.
3. A discharged battery can freeze. A
frozen battery must be thawed out before connecting the jumper cables.
4. There should be no contact be-
tween the two vehicles; otherwisecurrent may flow when the positive terminal is connected.
5. The discharged battery must be correctly connected to the vehicleelectrical system.
6. Run the engine of the vehicle sup- plying current.
7. Connect the jumper cables as fol-
lows:
(1) Connect one end of one jumper cable to the positive terminal of the flat battery, and the other end to the positive terminal of the booster battery.
(2) Connect one end of the other jumper cable to the negative ter-minal of the booster battery, and

4
CORROSION PREVENTION AND APPEARANCE CARE
23
4
IN CASE OF EMERGENCY
23
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 engine coolant leakingfrom the radiator, hoses or under the car. (If the air conditioning had been in use, it is normal for coldwater to be draining from it when you stop).
!WARNING:
While the engine is running, keep hair, hands, long hair and clothing away from moving parts such as the fan and drive belts to preventinjury.
!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.
5. If the water pump drive belt is bro- ken or engine coolant is leaking out, stop the engine immediately and call the nearest Hyundai dealer for assistance.!WARNING:
Do not remove the radiator cap when the engine is hot. This can allow coolant to be blown out of the open- ing and cause serious burns.
6. If you cannot find the cause of the overheating, wait until the engine temperature has returned to nor-mal. Then, if the engine coolant has been lost, carefully add coolant to the reservoir (page 8-12) to bringthe fluid level in the reservoir up to the halfway mark.
7. Proceed with caution, keeping alert for further signs of overheating. Ifoverheating happens again, call a Hyundai dealer for assistance.
CAUTION:
Serious loss of engine coolant indi-cates there is a leak in the coolingsystem and this should be checked as soon as possible by a Hyundai dealer.
!

44IN CASE OF EMERGENCY
26
G290B03P-AAT Adjustment After Headlight Assembly Replacement If the vehicle has had front body repair and the headlight assembly has been replaced, the headlight aiming should be checked using the aiming screen asshown in the illustration. Turn on the headlight switch. (Low Beam Position)
1. Adjust headlights so that main axis
of light is parallel to center line of the body and is aligned with point "P"shown in the illustration.
2. Dotted lines in the illustration show
center of headlights.
5. Open the hood.
6. Draw the vertical line (through the
center of each headlight beam pat- tern) and the horizontal line (through the center of each headlight beam pattern) on the aiming screen.And then, draw a horizontal parallel line at 30 mm (1.18 in.) under the horizontal line.
7. Adjust each cut-off line of the low beam to the parallel line with a phillipsscrewdriver - VERTICAL AIMING.
8. Adjust each cut-off line of the low beam to the each vertical line with aphillips screwdriver - HORIZONTALAIMING.
Horizontal aiming
Verticalaiming
G290A01P-1
Truck
G290B01L
LW
H
H Cut-off line
Ground line
"P"
Horizontal line
30mm (1.18 in.) Vertical line
HEADLIGHT AIMING ADJUSTMENT
G290A03P-AAT Before performing aiming adjustment, make sure of the following.
1. Keep all tires inflated to the correct pressure.
2. Place the vehicle on level ground
and press the front bumper and rear bumper down several times.
3. See that the vehicle is unloaded
(except for full levels of coolant,engine oil and fuel, and spare tire, jack, and tools). Have the driver or equivalent weight placed in driver'sseat.
4. Clean the head lights lens and turn
on the headlight (Low beam).
Minibus/Van
G290A02P
Horizontal aiming
Verticalaiming

6VEHICLE MAINTENANCE REQUIREMENTS
2MAINTENANCE INTERVALS
F010C01A-GAT
Specified Scheduled Procedures
These are the procedures such as
inspections, adjustments and replace- ments that are listed in the mainte-nance charts starting on page 6-4. These procedures must be performed at the intervals shown in the mainte-nance schedule to assure that your warranty remains in effect. Although it is strongly recommended that they beperformed by the factory-trained or distributor-trained technicians at your Hyundai dealer, these procedures maybe performed at any qualified service facility. F010D01A-AAT
General Checks
These are the regular checks you should perform when you drive your Hyundai or you fill the fuel tank. A list of these items will be found on page8-6.
F010A01A-GAT Service Requirements To assure that you receive the great- est number of kilometers of satisfying operation from your Hyundai, certain maintenance procedures must be per-formed. Although careful design and engineering have reduced these to a minimum, those that are required areof the utmost importance.It is your responsibility to have thesemaintenance procedures performed to comply with the terms of the warran- ties covering your new Hyundai. TheService Passport supplied with your new vehicle provides further informa- tion about these warranties.
F010B01A-AAT
Maintenance Requirements
The maintenance required for your
Hyundai can be divided into three main areas: o Specified scheduled procedures o General checks o Do-it-yourself maintenance It is suggested that genuine Hyundai
service parts be used for any requiredrepairs or replacements. Other parts of equivalent quality such as engine oil, engine coolant, manual or autotransaxle oil, brake fluid and so on which are not supplied by Hyundai Motor Company or its distributor maybe used without affecting your war- ranty coverage but you should always be sure these are equivalent to thequality of the original Hyundai parts. Your Service Passport provides fur- ther information about your warrantycoverage.

6VEHICLE MAINTENANCE REQUIREMENTS
6
50 40I I I I I I I I I I I I
KILOMETERS X 1000MONTHS
NO.
1 2 3 4 5 6 7 8 9
1011 12 13 14 15 16 17 18 19 20 21 22 DESCRIPTION
GENERAL MAINTENANCE ENGINE COOLANT MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL TRANSFER CASE OIL REAR AXLE OIL CLUTCH / BRAKE PEDAL FREE PLAY CLUTCH / BRAKE OIL RESERVOIR BRAKE HYDRAULIC FLUID FRONT BRAKE PADS FRONT BRAKE CALIPERS / CYLINDERS / DISC REAR BRAKE DRUMS / LININGS / CYLINDERS HANDBRAKE TIRE CONDITION / PRESSURE EXHAUST SYSTEM / MOUNTING STEERING JOINT / RACK / BOX OIL LEAKS SUSPENSION JOINT / SEALS FRONT WHEEL BEARING ENGINE COOLANT HOSES BRAKE PIPE CORROSION SEATBELTS / MOUNTINGS HEAD LAMPS AIR CONDITIONER FILTER (FOR EVAPORATOR AND BLOWER UNIT)
G020A05P-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
80 64
I
R II I I I I I I I I I I I I I 90 72
I I I I I I I I I I I I I
70 56
I I I I I I I I I I I I
6048
I I I I I I I I I I I I I I I I I I
4032
I
R II I I I I I I I I I I I I I
30 24
I I I I I I I I I I I I I
20 16
I I I I I I I I I I I I I I I I I108
I I I I I I I I I I I I
5 4
See Note (1)
Note : (1) For every 40,000 KM or 24 months, whichever occurs first : "R" (2) For every 20,000 KM or 12 months, whichever occurs first : "I"
(3) For every 48,000 KM or 24 months, whichever occurs first : "R"
(4) For every 20,000 KM or 12 months, whichever occurs first : "R"
See Note (4)
See Note (2) See Note (3)