Hyundai Terracan 2003 Owner's Manual

OWNER MAINTENANCE 6-9
Type
RC10PYPB4 (CHAMPION) PFR5N-11 (NGK)
Remark
Unleaded G070A03Y-AAT CHANGING THE AIR CLEANER FIL- TER The replacement of air cleaner filter is per- formed in the following manner.
1. Unsnap the clips around the cover.
2. When this is done, the cover can be lifted
off, the old filter removed and the new filter put in its place.
Genuine Hyundai replacement parts are rec-ommended. CAUTION:
o Operating your vehicle without a proper air cleaner filter in place can result in excessive engine wear.
o When removing the air cleaner filter, be careful that dust or dirt does not enterthe air intake. These may result in dam-age to the air cleaner filter.
G070A01HPG080A01HP
ZG080A2-E
WINDSCREEN WIPER BLADES
G060B03L-EAT
Replacing the Spark Plugs
The spark plugs should be changed at the
intervals specified in the vehicle maintenance schedule in Section 5 or whenever engine per-formance indicates they should be changed.Symptoms that suggest poor spark plug perfor-mance include engine misfiring under load, lossof fuel economy, poor acceleration, etc. Whenspark plugs are replaced, always use sparkplugs recommended by Hyundai. The use ofother spark plugs can result in loss of perfor-mance, radio interference or engine damage.
NOTE:
o When replacing the spark plug, Genuine Hyundai Replacement Parts are recom-mended.
Recommended Spark Plugs: The wiper blades should be carefully inspected
from time to time and cleaned to remove accu-mulations of road film or other debris.
To clean the wiper blades and arms, use a
clean sponge or cloth with a mild soap ordetergent and water.
If the wipers continue to streak or smear the
glass, replace them with genuine Hyundai re-placement parts or their equivalent.
NOTE:
o Do not operate the wipers on dry glass. This can result in more rapid wear of thewiper blades and may scratch the glass.
o Keep the blade rubber out of contact with petroleum products such as engineoil, petrol, etc.
o It is recommended that spark plugs be
changed by an authorized Hyundai dealer.
WARNING: It is recommended that the engine be cool
or cold when changing the spark plugs. If the engine is hot, you could burn yourselfon the insulated connector, the spark plugor the engine itself.

OWNER MAINTENANCE
6-10 1. To check the transmission lubricant level,
the vehicle should be placed on level ground and the level plug removed with a suitablespanner.
2. If the level is correct, lubricant should begin to drip from the plug orifice. In this case theplug should be replaced. If the level is incorrect, lubricant should be added until it begins to drip from the plugorifice at which time the plug should bereplaced.
To Check the Transmission Oil Level
SSA6100B
Park the car on level ground with the engine off.
1. Using a wrench of the correct size, loosen the oil filler bolt turning it counterclockwise and remove it with your fingers.
2. Use your finger to feel inside the hole. The oil level should be at its bottom edge. If it isnot, check for leaks before adding oil. Torefill the transmission or bring the oil level
G100A01HP-EAT
MANUAL TRANSMISSION LUBRICANT
The transmission lubricant should be checkedand/or changed at intervals specified in themaintenance schedule. Recommended Lubricant Use only HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4). CAUTION: The transmission lubricant level should onlybe checked when the engine is cold to pre-lude the possibility of personal injury bycontact with hot components.
G090A01HP
HPG090A1-E
WINDSCREEN WASHER RESERVOIR
REPLENISHMENT The level of windscreen washer fluid available
should be checked on a daily basis. The level of fluid will be visible through the side of thereservoir. When the fluid is to be replenished,only a proprietary screen wash additive shouldbe used and in the concentration recommendedby the manufacturer. The windscreen washerreservoir has a total capacity of 4.5 litres.
CAUTION: Engine coolant anti freeze must not be used
in the windscreen washer system since dam- age to the paintwork may result.
Undiluted windscreen washer additive must
not be allowed to come into contact with thepaintwork. If spillage occurs, flush the af-fected area immediately with water. Do notoperate the windscreen washer for more than 15 seconds continuously or when thereservoir is empty since damage to thewasher pump will result.
G100A01HP
Drain plug
Filler plug

OWNER MAINTENANCE 6-11
G110A04HP-EAT
AUTOMATIC TRANSMISSION LUBRI- CANT Transmission lubricant should be changed at
those intervals specified in the vehicle mainte- nance schedule in Section 5.
NOTE: Basically automatic transmission fluid is red
color. As driving distance increases, the fluid color turns darkish red gradually. It isnormal condition and you should not usefluid color as a criterion for replacing thetransmission fluid.
You must replace the automatic transmis-
sion fluid in accordance with intervals speci-fied in the vehicle maintenances schedule insection 5. Recommended Lubricant
Use only MOBIL DEXRON- II. Damage caused
by a nonspecified fluid is not covered by your new vehicle limited warranty. Transmission Fluid Capacity
The fluid capacity of the automatic transmission
is 10.5 litres (Petrol)/ 11.8 litres (Diesel). CAUTION: The transmission fluid level should be
checked when the engine is at normal oper- ating temperature. This means that the en-gine, radiator, exhaust system etc., are veryhot so you should exercise great care not toburn yourself during this procedure. To Check the Transmission Fluid Level
Park the car on level ground with the parking
brake engaged. When the transmission fluid level is checked, the transmission fluid shouldbe at normal operating temperature and theengine idling.
Whilst the engine is idling, apply the brakes and
move the gear selector level from "P" to each ofits other positions — "R", "N", "D", "2", "L" —and then return to "N" or "P". With the enginestill idling:
1. Open the bonnet, being careful to keep hands and clothing clear of any moving parts.
up, add oil slowly until it reaches the properlevel. Do not overfill.
3. Replace the bolt and washer, screw it in with your fingers and then tighten securely withthe wrench.
G110D03HP.DAG
G110D01HP-E
Petrol Engine
2. Remove the transmission dipstick, wipe it clean, reinsert the dipstick as far as it will go, then remove it again. Now check the fluidlevel on the dipstick. It should be in the"HOT" range on the dipstick. G110D04HP-E
Diesel Engine

OWNER MAINTENANCE
6-12
3. If the transmission fluid level is low, use a
funnel to add transmission fluid through the dipstick tube until the level reaches the "HOT"range. Do not overfill.
WARNING: The electric engine cooling fan automatical-
ly switches on and off according to engine temperature. Be careful to keep away fromthe fan during this check as it may switch onat any time.
WARNING (Diesel only): Never work on injection system with engine
running or within 30 seconds after shutting off engine. High pressure pump, rail, injec-tors and high pressure pipes are subject tohigh pressure even after the engine stopped.The fuel jet produced by fuel leaks maycause serious injury, if it touch the body.People using pacemakers should not move
G110D03Y
Fluid level should be within "HOT" range
than 30cm closer to the ECU or wiring har- ness within the engine room whilst engineis running, since the high currents in theCommon Rail system produce considerablemagnetic fields.
NOTE: Only lint free cloth should be used for wip-
ing the dipstick. The presence of lint within the transmission may cause problems withthe normal function of the transmission.
G120E01HP.DAG
SG120A1-E
BRAKE SYSTEM CHECKING CAUTION: Correct operation of the braking system is essential to the safe operation of the vehicleand therefore, any maintenance operationsother than those listed below should beentrusted to a Hyundai dealer. SG120C2-E
Brake Fluid Recommendations Only brake fluid conforming to DOT 3 or DOT 4 specifications or higher may be used in thebraking system. Care should be taken to ob-serve the instructions and precautions printedupon the container. SG120D1-E
Brake Fluid Level
The fluid level in the brake fluid reservoir shouldbe checked periodically. The level should bebetween the "MIN" and "MAX" marks on theside of the reservoir. If the level is at or belowthe "MIN" mark, fluid should be added havingcarefully cleaned the area surrounding the res-ervoir cap to ensure that dirt is not allowed toenter the system. It should be borne in mindthat the brake fluid level will decrease slightlyas the friction linings of the pads and shoesbecome worn and that this is a normal condi-tion. WARNING: Brake fluid is hygroscopic and should never be stored in an unsealed container. Thepresence of water in the braking system willcause vapour locks and increase the possi-bility of brake fade along with promoting

OWNER MAINTENANCE 6-13
G130A01HP.DAG
corrosion within the braking system. The brake fluid must be changed at the specifiedtime or mileage interval to ensure continuedsafe operation of the system. Brake fluid willcause rapid and serious damage topaintwork. If accidental spillage occurs, theaffected area must be rinsed with waterimmediately. Do not allow brake fluid tocome into contact with the eyes or to beingested and ensure that fluid is safely storedaway form the reach of children.
SG130A1-C
CHECKING THE CLUTCH FLUID To Check the Clutch Fluid The clutch fluid level in the master cylinder
should be checked when performing other un- der bonnet checks. The system should bechecked for leakage at the same time.
Ensure that the clutch fluid level is always
between the "MAX" and "MIN" level markingson the fluid reservoir. Fill as required. Fluid lossindicates a leak in the clutch system whichshould be inspected and repaired immediately. SG130B2-E
Adding Fluid
Recommended brake fluid conforming to DOT
3 or DOT 4 should be used. The reservoir capmust be fully tightened to avoid contaminationfrom foreign matter or moisture.
CAUTION: Brake fluid is hygroscopic and should never
be stored in an unsealed container. Do not allow petroleum base fluid to contaminatethe brake fluid since damage to the rubberseals of the system may result.
WARNING: Brake fluid will cause rapid and serious
damage to paintwork. If accidental spillage occurs, the affected area must be rinsedwith water immediately. Do not allow brakefluid to come into contact with the eyes or tobe ingested and ensure that fluid is safelystored away form the reach of children.
Petrol Engine
G130A03HP-E
Diesel Engine

OWNER MAINTENANCE
6-14
SG140D1-E
Off Season Maintenance
The air conditioning must be run for ten minutes
or so weekly during periods when the system would not normally be used to ensure that thecompressor and seals are lubricated. If thisprecaution is not observed the compressor sealsmay become stuck to the compressor shaft anddamaged when the system is next used result-ing in a loss of refrigerant and damage to thecompressor.
G140D01HP-D
G140D03HP
Petrol Engine
Generator pulley Idler pulley
Water pumppulley
COMP.pulley Auto tensioner
COMP. pulley
Crankshaft pulley
Crankshaft pulley
Tension pulley
HPG140B1-E
Compressor Drive Belt The air conditioning compressor drive belt should be checked to ensure freedom from damage orexcessive wear and correct tension. The belttension is correct when the belt deflects byabout 0.3 inches (8 mm) when a force of 98 Nis applied to the belt halfway between the com-pressor and crankshaft pulleys. Adjustment ofthe belt should be entrusted to a Hyundai dealer. NOTE: The compressor drive belt tension for dieselengine is adjusted automatically.Diesel Engine
SG140A1-E
AIR CONDITIONING SYSTEM MAINTENANCECondenser
Ensure that the condenser is periodically in-
spected and that accumulations of dirt, dead insects and leaves etc, are removed to ensurethat the efficiency of the system is not impaired.Care must be exercised to ensure that thecondenser fins are not damaged during clean-ing.
SG140C2-E
Checking the Refrigerant
1. Start the engine and run at idle for several minutes with the refrigeration system run- ning at the coldest setting.
2. If the air coming out of the in-dash vents is not cold, have the air conditioning systeminspected by your Hyundai dealer.
CAUTION: Running the air conditioning system for ex-
tended periods of time with a low refrigerant level may damage the compressor.

OWNER MAINTENANCE 6-15
YG170A1-E CLUTCH PEDAL
SSA6160A
0.24~0.51 in. (6~13 mm)
The clutch pedal freeplay must lie within the limits shown. Incorrect freeplay can result inpremature wear of the clutch linings and re-lease bearing. Excessive free-play can result ingear selection difficulties. If the freeplay is incorrect, the clutch cable should be adjusted by a Hyundai dealer. G170A01A-GAT
CHECKING BRAKE PEDAL FREEPLAY
With the engine off, press down on the brake
pedal several times to reduce the vacuum in the brake booster.
Then, using your hand, press down slowly on
the brake pedal until you feel a change inresistance. This is the brake pedal freeplay.The freeplay should be within the limits speci-fied in the illustration. If it is not, have it inspect-ed by your Hyundai dealer and adjusted orrepaired if necessary.
SSA6170A
0.12 ~ 0.31 in. (3 ~ 8 mm)
To check the steering wheel free-play, stop the car with the wheels pointed straight ahead andgently move the steering wheel back and forth.Use very light finger pressure and be sensitiveto changes in resistance that mark the limits ofthe free-play. If the free-play is greater than specified, have it inspected by your Hyundai dealer and adjustedor repaired if necessary.
G150A01HP
Maximum
1.18 in (30 mm)
YG180A1-E STEERING WHEEL

OWNER MAINTENANCE
6-16 If a belt is loose, adjust it by:
1. Loosen the adusting bolts just enough so that the components can be moved.
2. Whilst pulling outward on the pry bar or screw driver, test the belt deflection with your thumb.
3. After tightening the adjusting bolts, be sure to recheck the belt tension. Overtighteningdrive belts can cause excessive wear andfailure in driven components and belts.
YG190A1-E
ADJUSTING DRIVE BELTS YG200A1-E
CHECKING ENGINE DRIVE BELTS
1. With the engine turned off, check the belts for cracks, fraying, or excessive wear. Re- place the belt if it is in poor condition.
2. With your thumb (with a force approx. 10 kg) press on each belt midway between thepulleys. Each belt should deflect no morethan the amount shown in figure.
G190D01HP
G190D03HP
Petrol Engine
Generator pulley Idler pulley
Water pumppulley
COMP.pulley Autotensioner
Crankshaft pulley
Generator pulley Power steering pulley
Idler pulley Tension pulley
COMP. pulley Tension pulleyTension pulley
Tension pulley
Crankshaft pulley Powersteeringpulley
Diesel Engine
G180A01A-GAT
CHECKING BRAKE PEDAL CLEARANCE
95 in. (75 mm)
SSA6180A
You need a helper to check the brake pedal
clearance. With the engine running, have your helper press down on the brake pedal severaltimes and then hold it down with a force of about490 N (50 Kg, 110 lbs). The brake pedal clear-ance is the distance from the top surface of thebrake pedal to the asphalt sheeting under thefloor mat.
If the brake pedal clearance is not within the
limits specified in the illustration, have it in-spected by your Hyundai dealer and adjustedor repaired if necessary.

OWNER MAINTENANCE 6-17
DG200B1-E
INDIVIDUAL CIRCUIT FUSES
DG200A1-E
FUSIBLE LINKS
The fusible link prevents damage to the wiring
harness in the event of an electrical system malfunction. Failure of a fusible link is indicativeof a serious overload condition having occurredand therefore the electrical system should bechecked by a Hyundai dealer before a replace-ment link is fitted.
WARNING: Under no circumstances should a fusible
link be replaced with anything other than a new link of the same rating. The use ofhigher rated links or other means of con-necting the circuit will create a potential firehazard.
G200A01HP
Bad
GoodG200B01HP.DAG
The fuse box containing the individual circuit
fuses is located on the lower portion of the dashboard adjacent to the bonnet release. Thefuse box cover is removed by pushing lightlyand then releasing the lid. A fuse rating grid willbe found on the reverse side of the cover. In theevent of fuse failure, the fuse should be re-placed with one of equivalent rating. A fuseremoval tool is provided within the fuse box tofacilitate replacement. In the event of a replacement fuse failing shortly
after installation a malfunction within the circuitprotected by that fuse is indicated. The circuitshould be checked by a Hyundai dealer at thefirst available opportunity.
AXA6201B
Good
G200B03YBurned out
WARNING: The use of replacement fuses having a high-
er rating than specified or other means of connecting the circuit will create a potentialfire hazard.

OWNER MAINTENANCE
6-18 YG210A1-E
CHECKING ELECTRIC COOLING FANS CAUTION:
The cooling fan is controlled by engine cool- ant temperature and may sometimes oper-ate even when the engine is not running. Donot touch the radiator fan until it is com-pletely stopped. As the coolant temperature decreases the fan will automatically shut off. This is anormal condition.
Checking Engine Cooling Fan The engine cooling fan should automaticallycome on if the engine coolant temperature ishigh.
Checking Condenser Cooling Fan The condenser cooling fan (in front of the con-denser) should come on automatically whenev-er the air conditioner is in operation.
DG210A1-E
BATTERY MAINTENANCE WARNING:
Motor vehicle batteries contain sulphuricacid which is corrosive and poisonous. Hy-drogen gas is emitted from the battery whichis explosive when combined with oxygen.The following precautions must be strictlyobserved to avoid personal injury or dam-age to the vehicle.
o If battery electrolyte is spilled onto skin or into eyes, the effected area must be flushedwith copious amounts of water and medicalassistance sought.
o If battery electrolyte is ingested, copious amounts of water or milk followed by an ant-acid (raw egg or milk of magnesia) must bedrunk. Vomiting should not be induced andmedical assistance must be sought.
o Batteries must only be charged in well venti- lated areas from which naked lights or sourc-es of sparks are excluded.
o Ensure that children, pets or other unautho- rized persons are kept away from batteries.
o Do not allow anything to bridge the positive (+) and negative (-) terminals of the battery.
o Never invert the battery.
The battery fitted during production is of the"Maintenance Free" type.
G210A01HP.DAG
G210A03HP-E
Petrol Engine
Diesel Engine