brake Hyundai H-1 (Grand Starex) 2009 Repair Manual

73
Maintenance
OTQ077066
1. Power steering fluid reservoir
2. Automatic transmission fluid dipstick
(if equipped)
3. Engine oil filler cap
4. Brake fluid reservoir
5. Fuse box
6. Negative battery terminal
7. Positive battery terminal
8. Engine coolant reservoir
9. Engine oil dipstick
10. Radiator cap
11. Windshield washer fluid reservoir
12. Air cleaner
■
■
Gasoline Engine
* The actual engine room in the vehicle may differ from the illustration.

Maintenance
6
7
OWNER MAINTENANCE
G030000AEN
The following lists are vehicle checks and
inspections that should be performed by
the owner or an authorized HYUNDAIdealer at the frequencies indicated to
help ensure safe, dependable operation
of your vehicle.
Any adverse conditions should be
brought to the attention of your dealer as
soon as possible.
These Owner Maintenance Checks are
generally not covered by warranties and
you may be charged for labor, parts and
lubricants used. Owner maintenance schedule
G030101AUN
When you stop for fuel:
Check the engine oil level.
Check coolant level in coolant reser-
voir.
Check the windshield washer fluid level.
Look for low or under-inflated tires. G030102AUN
While operating your vehicle:
Note any changes in the sound of the
exhaust or any smell of exhaust fumes
in the vehicle.
Check for vibrations in the steering wheel. Notice any increased steering
effort or looseness in the steering
wheel, or change in its straight-aheadposition.
Notice if your vehicle constantly turns slightly or “pulls” to one side when trav-
eling on smooth, level road.
When stopping, listen and check for unusual sounds, pulling to one side,
increased brake pedal travel or “hard-
to-push” brake pedal.
If any slipping or changes in the oper- ation of your transmission occurs,
check the transmission fluid level.
Check automatic transmission P (Park) function.
Check parking brake.
Check for fluid leaks under your vehicle (water dripping from the air condition-
ing system during or after use is nor-mal).
WARNING
Be careful when checking your
engine coolant level when the
engine is hot. Scalding hot coolant
and steam may blow out under
pressure. This could cause burns
or other serious injury.

77
Maintenance
G030103AUN
At least monthly:
Check coolant level in the enginecoolant reservoir.
Check the operation of all exterior lights, including the stoplights, turn sig-
nals and hazard warning flashers.
Check the inflation pressures of all tires including the spare. G030104AUN
At least twice a year
(i.e., every Spring and Fall):
Check radiator, heater and air condi- tioning hoses for leaks or damage.
Check windshield washer spray and wiper operation. Clean wiper blades
with clean cloth dampened with wash-er fluid.
Check headlight alignment.
Check muffler, exhaust pipes, shields and clamps.
Check the lap/shoulder belts for wear and function.
Check for worn tires and loose wheel lug nuts. G030105AUN-EU
At least once a year:
Clean body and door drain holes.
Lubricate door hinges and checks, and
hood hinges.
Lubricate door and hood locks and latches.
Lubricate door rubber weatherstrips.
Check the air conditioning system.
Check the power steering fluid level.
Inspect and lubricate automatic trans- mission linkage and controls.
Clean battery and terminals.
Check the brake fluid level.

Maintenance
8
7
SCHEDULED MAINTENANCE SERVICE
G040000AUN
Follow Normal Maintenance Schedule if
the vehicle is usually operated where
none of the following conditions apply. If
any of the following conditions apply, fol-
low Maintenance Under Severe Usage
Conditions.
Repeated short distance driving.
Driving in dusty conditions or sandy areas.
Extensive use of brakes.
Driving in areas where salt or other corrosive materials are being used.
Driving on rough or muddy roads.
Driving in mountainous areas.
Extended periods of idling or low speed operation.
Driving for a prolonged period in cold temperatures and/or extremely humid
climates.
More than 50% driving in heavy city traffic during hot weather above 32°C(90°F).
If your vehicle is operated under the
above conditions, you should inspect, replace or refill more frequently than the
following Normal Maintenance Schedule.After 96 months or 120,000 km (80,000 miles) continue to follow the prescribed
maintenance intervals.

11
Maintenance
NORMAL MAINTENANCE SCHEDULE (CONT.)
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.*5
: When adding coolant, use only a qualified coolant additive for your vehicle and never mix hard water in the coolant filled at
the factory. An improper coolant mixture can result in serious malfunction or engine damage.
* 6
: For your convenience, it can be replaced prior to it's interval when you do maintenance of other items.
MAINTENANCE
INTERVALS
MAINTENANCE ITEMNumber of months or driving distance, whichever comes first
Months 12 24 36 48 60 72 84 96
Miles×1,000 10 20 30 40 50 60 70 80
Km×1,000 15 30 45 60 75 90 105 120
Cooling system
For Europe
Engine coolant * 5
Except Europe
Battery condition I I I I I I I I
All electrical systems I I I I
Brake lines, hoses and connections I I I I I I I I
Brake pedal I I I I
Parking brake I I I I
Brake fluid
III IIIII
Disc brakes and pads I I I I I I I I
Power steering fluid and hoses I I I I I I I I
At first, replace at 100,000 km (62,500 miles) or 60 months:
after that, replace every 40,000 km (25,000 miles) or 24 months *
6
At first, replace at 48,000 km (30,000 miles) or 24 months:
after that, replace every 40,000 km (25,000 miles) or 24 months *
6
Inspect “Coolant level and leak” every day
Inspect “Water pump” when replacing the drive belt or timing belt
7

Maintenance
14
7
Severe driving conditions
A : Repeated short distance driving
B : Extensive idling
C : Driving in dusty, rough roads
D : Driving in areas using salt or other corrosive
materials or in very cold weather
E : Driving in sandy areas
F : More than 50 % driving in heavy city traffic during hot weather above 32°C (90°F) G : Driving in mountainous areas
H : Towing a trailer
I : Driving for patrol car, taxi, commercial car or vehicle tow-
ing
J : Driving over 140 km/h (87 mile/h)
K : Driving over 170 km/h (106 mile/h)
L : Frequently driving in stop - and - go conditions
Steering gear rack, linkage and boots I C, D, E, F, G
Propeller shaft I Every 15,000 km (10,000 miles) or 12 months C, E
Front suspension ball joints I C, D, E, F, G
Disc brakes and pads, calipers and rotors I C, D, E, G, H
Parking brake I C, D, G, H
Climate control air filter (if equipped) R C, E
MAINTENANCE ITEMMaintenance
operation Maintenance intervals
Driving condition
Inspect more frequently
depending on the condition
Inspect more frequently
depending on the condition
Inspect more frequently
depending on the condition
Inspect more frequently
depending on the condition
Replace more frequently
depending on the condition

Maintenance
16
7
G050600AUN
Vapor hose and fuel filler cap
The vapor hose and fuel filler cap should
be inspected at those intervals specified
in the maintenance schedule. Make sure
that a new vapor hose or fuel filler cap iscorrectly replaced.
G050700AUN
Vacuum crankcase ventilation hoses (if equipped)
Inspect the surface of hoses for evidence
of heat and/or mechanical damage. Hard
and brittle rubber, cracking, tears, cuts,
abrasions, and excessive swelling indi-
cate deterioration. Particular attention
should be paid to examine those hose
surfaces nearest to high heat sources,
such as the exhaust manifold. Inspect the hose routing to assure that the hoses do not come in contact with
any heat source, sharp edges or movingcomponent which might cause heat dam-
age or mechanical wear. Inspect all hose
connections, such as clamps and cou-
plings, to make sure they are secure, and
that no leaks are present. Hoses should
be replaced immediately if there is any
evidence of deterioration or damage. G050800AEN
Air cleaner filter
A Genuine HYUNDAI air cleaner filter is recommended when the filter isreplaced.
G050900AUN
Spark plugs (for gasoline engine)
Make sure to install new spark plugs of
the correct heat range. G051000AEN
Valve clearance (if equipped)
Inspect excessive valve noise and/or
engine vibration and adjust if necessary.
An authorized HYUNDAI dealer should
perform the operation.
G051100AUN Cooling system
Check cooling system components, such
as radiator, coolant reservoir, hoses and
connections for leakage and damage.
Replace any damaged parts.
G051200AUN Coolant The coolant should be changed at the
intervals specified in the maintenance
schedule.
G051300AUN
Manual transmission fluid (if equipped)
Inspect the manual transmission fluid
according to the maintenance schedule.
G051400ATQ
Automatic transmission fluid (if equipped)
The fluid level should be in the "HOT"
range of the dipstick, after the engine
and transmission are at normal operating
temperature. Check the automatic trans-
mission fluid level with the engine run-
ning and the transmission in neutral, with
the parking brake properly applied.
✽✽
NOTICE
If your vehicle is not equipped with the automatic transmission level gauge,have the automatic transmission fluidinspected by an authorized Hyundai
dealer according to the maintenanceschedule.

717
Maintenance
G051500AUN Brake hoses and lines
Visually check for proper installation,
chafing, cracks, deterioration and any
leakage. Replace any deteriorated or
damaged parts immediately.
G051600AUN Brake fluid
Check brake fluid level in the brake fluid
reservoir. The level should be between
“MIN” and “MAX” marks on the side of
the reservoir. Use only hydraulic brake
fluid conforming to DOT 3 or DOT 4specification.
G051700AUN
Parking brake
Inspect the parking brake system includ-
ing the parking brake lever and cables.
G051900AUN
Brake discs, pads, calipers and
rotors
Check the pads for excessive wear, discs
for run out and wear, and calipers for fluid
leakage.G052100AUN Suspension mounting bolts
Check the suspension connections for
looseness or damage. Retighten to the
specified torque.
G052200AUN
Steering gear box, linkage &
boots/lower arm ball joint
With the vehicle stopped and engine off,
check for excessive free-play in the
steering wheel.
Check the linkage for bends or damage.
Check the dust boots and ball joints for
deterioration, cracks, or damage.
Replace any damaged parts. G052300AEN
Power steering pump, belt and hoses
Check the power steering pump and
hoses for leakage and damage. Replace
any damaged or leaking parts immedi-
ately. Inspect the power steering belt (or
drive belt) for evidence of cuts, cracks,
excessive wear, oiliness and proper ten-
sion. Replace or adjust it if necessary.
G052500AUN
Air conditioning refrigerant (if equipped)
Check the air conditioning lines and con-
nections for leakage and damage.

Maintenance
22
7
BRAKE AND CLUTCH (IF EQUIPPED) FLUID
G080100AEN
Checking the brake fluid level
Check the fluid level in the reservoir peri-
odically. The fluid level should be
between MAX and MIN marks on the
side of the reservoir.
Before removing the reservoir cap and
adding brake fluid, clean the area around
the reservoir cap thoroughly to prevent
brake fluid contamination. If the level is low, add fluid to the MAX
level. The level will fall with accumulated
mileage. This is a normal condition asso-
ciated with the wear of the brake linings.
If the fluid level is excessively low, have
the brake system checked by an author-
ized HYUNDAI dealer.
Use only the specified brake fluid. (Refer
to “Recommended lubricants or capaci-ties” in section 9.)
Never mix different types of fluid.
WARNING - Brake fluid
When changing and adding brake
fluid, handle it carefully. Do not let it
come in contact with your eyes. Ifbrake fluid should come in contact
with your eyes, immediately flush
them with a large quantity of fresh
tap water. Have your eyes examined
by a doctor as soon as possible.
WARNING - Loss of brake fluid
In the event the brake system
requires frequent additions of fluid,
the vehicle should be inspected by
an authorized HYUNDAI dealer.
OTQ077006
CAUTION
Do not allow brake fluid to contact the vehicle's body paint, as paint damage will result. Brake fluid,
which has been exposed to open air for an extended time should neverbe used as its quality cannot beguaranteed. It should be disposed
of properly. Don't put in the wrongkind of fluid. A few drops of miner- al-based oil, such as engine oil, inyour brake system can damage
brake system parts.

Maintenance
24
7
AUTOMATIC TRANSMISSION FLUID (IF EQUIPPED)
G100100ATQ
Checking the automatic transmis-
sion fluid level
✽✽ NOTICE
If your vehicle is not equipped with the automatic transmission level gauge,have the automatic transmission fluidinspected by an authorized Hyundai
dealer according to the maintenanceschedule.
If your vehicle is equipped with the
automatic transmission level gauge,
inspect the fluid level as follows.
The automatic transmission fluid level
should be checked regularly.
Keep the vehicle on the level ground with
the parking brake applied and check the
fluid level according to the following pro-
cedure.
1. Place the selector lever in N (Neutral) position and confirm the engine is run-
ning at normal idle speed.
2. After the transmission is warmed up sufficiently (fluid temperature 70~80°C
(158~176°F), for example by 10 min-
utes usual driving, move the shift leverthrough all positions then place the
selector lever in “N (Neutral) or P
(Park)” position. 3. Confirm that the fluid level is in “HOT”
range on the level gauge. If the fluid
level is lower, add the specified fluid
from the fill hole. If the fluid level is
higher, drain the fluid from the drain
hole.
4. If the fluid level is checked in cold con- dition (fluid temperature 20~30°C
(68~86°F) add the fluid to “C” (COLD)
line and then recheck the fluid level
according to the above step 2.
OTQ077008OTQ077009