maintenance Hyundai H-1 (Grand Starex) 2016 - RHD (UK, Australia) Owner's Guide

79
Maintenance
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.
*
1: Adjust alternator and power steering (and water pump drive belt) and air conditioner drive belt (if equipped). Inspect and if nec-
essary correct or replace.
*
2: Check the engine oil level and leak every 500 km or before starting a long trip.
*3: If good quality petrol meeting Europe Fuel standards (EN228) or equivalent, including fuel additives is not available, one bot-
tle of additive is recommended. Additives are available from your authorised HYUNDAI dealer along with information on how
to use them. Do not mix other additives.
G040300ETQ-EA
NORMAL MAINTENANCE SCHEDULE
Number of months or driving distance, whichever comes first
Months1224364860728496
Km×1,000153045607590105120
Drive belts *1DieselAt first, inspect 80,000 km or 48 months
after that, inspect every 20,000 km or 12 months
PetrolIIII
Engine oil and engine oil filter *2RRRRRRRR
Fuel additives *3Add every 15,000 km or 12 months
Air cleaner filter IIRIIRII
Spark plugPetrolReplace every 100,000 km
Vapour hose and fuel filler capII
Vacuum and crankcase ventilation
hosesPetrolIIII
Vacuum hose (for EGR & throttle body)
(if equipped)IIIIIIII
Vacuum pump and vaccum hoseDieselIIIIIIII
Vaccum pump oil hoseDieselIIIIIIII
MAINTENANCE
INTERVALS
MAINTENANCE
ITEM

Maintenance
10 7
NORMAL MAINTENANCE SCHEDULE (CONT.)
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.
*
4: This maintenance schedule depends on fuel quality. It is applicable only when using a qualified fuel <"EN590 or equivalent">.
If the diesel fuel specifications don't meet the EN590, it must be replaced more frequently. HYUNDAI recommends "every
7,500km inspection, every 15,000km replacement". If there are some important safety matters like fuel flow restriction, surging,
loss of power, hard starting problem etc., replace the fuel filter immediately regardless of maintenance schedule and consult an
authorised HYUNDAI dealer for details.
*
5: The fuel filter is considered to be maintenance free but periodic inspection is recommended for this maintenance schedule
depends on fuel quality. If there are some important safety matters like fuel flow restriction, surging, loss of power, hard start-
ing problem etc, replace the fuel filter immediately regardless of maintenance schedule and consult an authorised HYUNDAI
dealer for details.
*
6: When adding coolant, use only deionized water or soft water 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.
*
7: For your convenience, it can be replaced prior to it's interval when you do maintenance of other items.
Number of months or driving distance, whichever comes first
Months1224364860728496
Km×1,000153045607590105120
Fuel filter cartridge *4DieselIRIR
Fuel filter *5PetrolIRIR
Fuel lines, hoses and connectionsDieselIIII
PetrolII
Cooling systemInspect “Coolant level and leak” every day
Inspect “Water pump” when replacing the drive belt or timing belt
Engine coolant *6At first, replace at 210,000 km or 10 years:
after that, replace every 30,000 km or 24 months *7
Battery conditionIIIIIIII
MAINTENANCE
INTERVALS
MAINTENANCE
ITEM

711
Maintenance
NORMAL MAINTENANCE SCHEDULE (CONT.)
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.
*
8: Rear axle oil should be changed anytime they have been submerged in water.
Number of months or driving distance, whichever comes first
Months1224364860728496
Km×1,000153045607590105120
All electrical systems
(including the light bulbs and switches)IIIIIIII
Brake lines, hoses and connectionsIIIIIIII
Brake pedalIIII
Parking brakeIIIIIIII
Brake fluidIIIIIIII
Disc brakes and padsIIIIIIII
Power steering fluid and hosesIIIIIIII
Steering gear rack, linkage and bootsIIIIIIII
Propeller shaft IIII
Tyre (pressure & tread wear) IIIIIIII
Front suspension ball jointsIIIIIIII
Bolt and nuts on chassis and bodyIIIIIIII
Air conditioner refrigerant (if equipped)IIIIIIII
Air conditioner compressor (if equipped)IIIIIIII
Climate control air filter (if equipped)RRRRRRRR
Manual transmission fluid (if equipped)II
Automatic transmission fluid (if equipped)II
Rear axle oil *8IIII
MAINTENANCE
INTERVALS
MAINTENANCE
ITEM

Maintenance
12 7
G040200BTQ-EA
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
The following items must be serviced more frequently on cars mainly used under severe driving conditions.
Refer to the chart below for the appropriate maintenance intervals.
R : Replace I : Inspect and if necessary, adjust, correct, clean or replace
Engine oil and engine oil filter R Every 7,500 km or 6 months
Air cleaner filter R C, E
Manual transmission fluid (if equipped) R Every 120,000 km C, D, E, G, H, I, K
Automatic transmission fluid (if equipped) R Every 100,000 km
Rear axle oil R Every 90,000 km C, E, G, H, I, K
MAINTENANCE ITEMMaintenance
operationMaintenance intervals
Driving condition
Replace more frequently
depending on the condition
A, B, C, E, F, G, H,
I, J, L
A, C, D, E, F, G, H,
I, K

713
Maintenance
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
K : Driving over 170 km/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 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
operationMaintenance 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
14 7
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS
G050100AUN
Engine oil and filter
The engine oil and filter should be
changed at the intervals specified in the
maintenance schedule. If the car is being
driven in severe conditions, more fre-
quent oil and filter changes are required.
G050200BUN
Drive belts
Inspect all drive belts for evidence of
cuts, cracks, excessive wear or oil satu-
ration and replace if necessary. Drive
belts should be checked periodically for
proper tension and adjusted as neces-
sary.
G050300ATQ-EA
Fuel filter (cartridge)
A clogged filter can limit the speed at
which the vehicle may be driven, damage
the emission system and cause multiple
issues such as hard starting. If an exces-
sive amount of foreign matter accumu-
lates in the fuel tank, the filter may
require replacement more frequently.
After installing a new filter, run the engine
for several minutes, and check for leaks
at the connections. We recommend that
the fuel filter be replaced by an authoized
HYUNDAI dealer.
G050400AEN-EA
Fuel lines, fuel hoses and con-
nections
Check the fuel lines, fuel hoses and con-
nections for leakage and damage. We
recommend that the fuel lines, fuel hoses
and connectionsr be replaced by an
authoized HYUNDAI dealer.
WARNING - Diesel only
Never work on injection system
with engine running or within 30
seconds after shutting off engine.
High pressure pump, rail, injectors
and high pressure pipes are sub-
ject to high pressure even after the
engine stopped. The fuel jet pro-
duced by fuel leaks may cause seri-
ous injury, if it touch the body.
People using pacemakers should
not move than 30cm closer to the
ECU or wiring harness within the
engine room whilst engine is run-
ning, since the high currents in the
Common Rail system produce con-
siderable magnetic fields.
CAUTION
If the fuel filter becomes clogged as
a result of using dirty or contami-
nated fuel or failure to replace it at
the specified interval, fuel supply
may become restricted, which will
result in damage to the fuel injec-
tion system. These damages can
cause drivability problems and in
the worst case total fuel system fail-
ure.
CAUTION
When you are inspecting the belt,
place the ignition switch in the
LOCK/OFF or ACC position.

715
Maintenance
G050600AUN-EA
Vapour hose and fuel filler cap
The vapour hose and fuel filler cap
should be inspected at those intervals
specified in the maintenance schedule.
Make sure that a new vapour hose or fuel
filler cap is correctly 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 moving
component 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
We recommend that the air cleaner filter
be replaced by an authoized HYUNDAI
dealer.
G050900BUN-EA
Spark plugs (for petrol engine)
Make sure to install new spark plugs of
the correct heat range.
G051000AEN-EA
Valve clearance (if equipped)
Inspect excessive valve noise and/or
engine vibration and adjust if necessary.
We recommend that the system be serv-
iced by an authorised HYUNDAI dealer.
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.
WARNING
Do not disconnect and inspect
spark plugs when the engine is hot.
You may burn yourself.

Maintenance
16 7
G051400ATQ-EA
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 fluid
inspected by an authorised HYUNDAI
dealer according to the maintenance
schedule.
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 4
specification.
G051700AUN
Parking brake
Inspect the parking brake system includ-
ing the parking brake lever and cables.
G051900AGD
Brake discs, pads, calipers and
rotors
Check the pads for excessive wear, discs
for run out and wear, and calipers for fluid
leakage.
For more information on checking the
pads or lining wear limit, refer to the
HYUNDAI web site.
(http://brakeman
ual.hmc.co.kr)
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.

717
Maintenance
ENGINE OIL
G060100CEN
Checking the engine oil level
1. Be sure the vehicle is on level ground.
2. Start the engine and allow it to reach
normal operating temperature.
3. Turn the engine off and wait for a few
minutes (about 5 minutes) for the oil to
return to the oil pan.
4. Pull the dipstick out, wipe it clean, and
re-insert it fully.5. Pull the dipstick out again and check
the level. The level should be between
F and L.
If it is near or at L, add enough oil to bring
the level to F.Do not overfill.
Use a funnel to help prevent oil from
being spilled on engine components.
Use only the specified engine oil. (Refer
to “Recommended lubricants and capac-
ities” in section 9.)
WARNING - Radiator hose
Be very careful not to touch the
radiator hose when checking or
adding the engine oil as it may be
hot enough to burn you.
OTQ077002LOTQ077003L
CAUTION - Diesel engine
Overfilling the engine oil may cause
severe dieseling due to churning
effect. It may lead to engine damage
accompanied with abrupt engine
speed increment, combustion noise
and white smoke emission.
CAUTION
• Do not overfill with engine oil.
Engine damage may result.
• Do not spill engine oil, when
adding or changing engine oil. If
you drop the engine oil on the
engine room, wipe it off immedi-
ately.
• When you wipe the oil level
gauge, you should wipe it with a
clean cloth. When mixed with
debris, it can cause engine dam-
age.

Maintenance
18 7
G060200AEN-EA
Changing the engine oil and filter
We recommend that the engine oil and
filter be replaced by an authorised
HYUNDAI dealer.
G070000BUN-EA
The high-pressure cooling system has a
reservoir filled with year-round antifreeze
coolant. The reservoir is filled at the fac-
tory.
Check the antifreeze protection and
coolant level at least once a year, at the
beginning of the winter season, and
before travelling to a colder climate.
G070100AEN-EA
Checking the coolant level
WARNING
Used engine oil may cause irrita-
tion or cancer of the skin if left in
contact with the skin for prolonged
periods of time. Used engine oil
contains chemicals that have
caused cancer in laboratory ani-
mals. Always protect your skin by
washing your hands thoroughly
with soap and warm water as soon
as possible after handling used oil.
ENGINE COOLANT
WARNING
Removing radiator
cap
• Never attempt to remove the radi-
ator cap whilst the engine is
operating or hot. Doing so might
lead to cooling system and
engine damage and could result
in serious personal injury from
escaping hot coolant or steam.
• Turn the engine off and wait until
it cools down. Use extreme care
when removing the radiator cap.
Wrap a thick towel around it, and
turn it counterclockwise slowly to
the first stop. Step back whilst
the pressure is released from the
cooling system. When you are
sure all the pressure has been
released, press down on the cap,
using a thick towel, and continue
turning counterclockwise to
remove it.
(Continued)CAUTION
• Do not drive with no engine
coolant. It may cause water pump
failure and engine seizure, etc.
• When the engine overheats from
low engine coolant, suddenly
adding engine coolant may cause
cracks in the engine. To prevent
damage, add engine coolant
slowly in small quantities.