brake Hyundai Terracan 2003 Service Manual

DO-IT-YOURSELF MAINTENANCE 6-9
coolant container, add the appropriate quan- tity of coolant to the radiator.
G050D03HP
G050D01HP
G050D02HP
NOTE: Gasoline Engine Only Before adding the coolant to the radiator, unscrew the flange bolt for fitting water outlet to escape the excess pressure. And if the coolant overflows from the hole while adding the coolant, screw the bolt and con- tinue to add the coolant. 4. Turn the radiator cap counterclockwise with-
out pressing down on it, until it stops. Thisrelieves any pressure remaining in the cool- ing system. And remove the radiator cap by pushing down and turning counterclockwise. Now fill the radiator with clean demineral-ized or distilled water. Continue to add clean demineralized or distilled water in small quan- tities until the fluid level stays up in the radiator neck.
5. Start the engine, top off the radiator with water and then add coolant to the reservoir until the level is between "LOW" and "FULL".
6. Replace the radiator and reservoir caps and check to be sure the drain cocks are fullyclosed and not leaking.
WARNING:The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper- ate even when the engine is not running.
Gasoline Engine only
The coolant level can be seen on the side of the plastic coolant reservoir. The level of the cool- ant should be between the "LOW" and "FULL" lines on the reservoir when the engine is cool. If the level is below the "LOW" mark, add engine coolant to bring it up between "LOW" and "FULL". If the level is low, inspect for coolant leaks and recheck the fluid level fre- quently. If the level drops again, visit your Hyundai dealer for an inspection and diagnosis of the reason.
G050D01HP-GAT To Change the Engine CoolantThe engine coolant should be changed at those intervals specified in the vehicle maintenance schedule in Section 5. CAUTION: Engine coolant can damage the finish of your car. If you spill engine coolant on the car, wash it off thoroughly with clean water.
1. Park the car on level ground, set the park-
ing brake and remove the radiator cap when cool.
2. Be sure your drain receptacle is in place. Open the drain cock on the radiator. Allowall the engine coolant to drain from the cooling system, then securely close the drain cock.
3. Check Section 9 for the capacity of the cooling system in your car. Then, followingthe manufacturer’s directions on the engine

DO-IT-YOURSELF MAINTENANCE
6-12
G110D02HP-GAT
To Check the Transmission Fluid Level
G110D03HP
Park the car on level ground with the parking brake engaged. When the transmission fluid level is checked, the transmission fluid should be at normal operating temperature and the engine idling.
G110C03HP-GAT
Transmission Fluid Capacity The fluid capacity of the automatic transmission
is; Gasoline - 10.5 liters (11.09 U.S. quarts) Diesel (2.9 CRDi) - 11.8 liters (12.47 U.S. quarts)
Diesel (2.5 TCI) - 8.2 liters (8.66 U.S. quarts)
WARNING: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 very hot. Exercise great care not to burn yourself during this procedure.
G110A01HP-GAT
CHECKING THE TRANSMISSION FLUID (AUTOMATIC) Transmission fluid in the automatic transmis- sion should be checked at those intervals speci- fied in the vehicle maintenance schedule in Section 5. G110B01HP-GAT Recommended FluidYour Hyundai automatic transmission is spe- cially designed to operate with DEXRON- II or
DEXRON -III. Damage caused by a nonspecified
fluid is not covered by your new vehicle limited warranty.
3. Replace the plug and washer, screw it in
with your fingers and then tighten securely with the wrench.
G110D01HP-D
Gasoline
G100B01HP-GAT To Check the Manual Transmission Fluid LevelG100B01HP
WARNING: It is always better to check the transmissionoil level when the engine is cool or cold. If the engine is hot, you should exercise great caution to avoid burning yourself on hot engine or exhaust parts. Park the car on level ground with the engine off.
1. Using a wrench of the correct size, loosen
the oil filler plug by turning it counterclock- wise 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. To refill the transmission or bring the oil level up,add oil slowly until it reaches the proper level. Do not overfill.

DO-IT-YOURSELF MAINTENANCE 6-13
G110D03Y
Fluid level should be within "HOT" range
G120A01A-AAT CHECKING THE BRAKESCAUTION: Because brakes are essential to the safe operation of the car, it is suggested that they be checked and inspected by your Hyundai dealer. The brakes should be checked and inspected for wear at those intervals specified in the vehicle mainte- nance schedule in Section 5.
WARNING: The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper- ate even when the engine is not running. Use extreme caution when working near the blades of the cooling fan, so that you are not injured by a rotating fan blade. As the en- gine coolant temperature decreases, the fan will automatically shut off. This is a normal condition. G120B02A-AAT Checking the Brake Fluid Level WARNING: Use caution when handling brake fluid. Itcan damage your vision if it gets into your eyes. It will also damage your vehicle’s paint if spilled on it and not removed immediately. G120C02A-AAT Recommended Brake FluidUse only hydraulic brake fluid conforming to DOT 3 or DOT 4 specifications in your braking system. Follow the instructions printed on the container. G120D01A-AAT To Check the Fluid LevelThe fluid level in the brake fluid reservoir should be checked periodically. The level should be between the "MIN" and "MAX" marks on the side of the reservoir. If the level is at or below the "MIN" mark, carefully add fluid to bring it up to "MAX". Do not overfill.
While the engine is idling, apply the brakes and move the gear selector lever from "P" to each of its other positions — "R", "N", "D", "2", "L" — and then return to "N" or "P". With the engine still idling:
1. Open the hood, being careful to keep hands,
long hair and clothing clear of any moving parts.
2. Remove the transmission dipstick, wipe it clean, reinsert the dipstick as far as it will go,then remove it again. Now check the fluid level on the dipstick. It should be in the "HOT" range on the dipstick.
3. If the transmission fluid level is low, use a funnel to add transmission fluid through thedipstick tube until the level reaches the "HOT" range. Do not overfill.
Diesel (2.9 CRDi)
Diesel (2.5 TCI)
G110D02HP

DO-IT-YOURSELF MAINTENANCE
6-14 G140A01A-AAT
AIR CONDITIONING CARE Keeping the Condenser Clean
The air conditioning condenser (and engine
radiator) should be checked periodically for accumulation of dirt, dead insects, leaves, etc. These can interfere with maximum cooling effi- ciency. When removing such accumulations, brush or hose them away carefully to avoid bending the cooling fans. G130B02A-AAT
To Replace the Fluid Recommended brake fluid conforming to DOT
3 or DOT 4 specification should be used. The reservoir cap must be fully tightened to avoid contamination from foreign matter or moisture.
NOTE: Do not allow any other liquids to contami-
nate the brake fluid. Seal damage will result.
WARNING:Use caution when handling brake fluid. It
can damage your vision if you get it in your eyes. It will also damage your vehicle’s paint if spilled on it and not removed immediately.
G130A01A-AAT
CHECKING THE CLUTCH FLUID To Check the Clutch Fluid
G130A01HP
The clutch fluid level in the master cylinder
should be checked when performing other un- der hood services. The system should be checked for leakage at the same time. Check to make certain that the clutch fluid level is always between the "MAX" and "MIN" level markings on the fluid reservoir. Fill as required. Fluid loss indicates a leak in the clutch system which should be inspected and repaired immediately. Consult your Hyundai dealer.
G120E02A-AAT
Adding Brake Fluid
WARNING: Handle brake fluid carefully. It can damage
your vision if it gets into your eyes. Use only DOT 3 or DOT 4 specification fluid from a sealed container. Do not allow the fluid can or reservoir to remain open any longer than required. This will prevent entry of dirt and moisture which can damage the brake sys- tem and cause improper operation.
To add brake fluid, first wipe away any dirt then
unscrew the fluid reservoir cap. Slowly pour the recommended fluid into the reservoir. Do not overfill. Carefully replace the cap on the reser- voir and tighten.
G120E01HP

DO-IT-YOURSELF MAINTENANCE 6-17
G160A01A-GAT CHECKING CLUTCH PEDAL FREE-PLAY With the engine off, press lightly on the clutch pedal until you feel a change in resistance. This is the clutch pedal freeplay. The freeplay should be within the limits specified in the illustration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.
SSA6160A
6 ~ 13 mm (0.24 ~ 0.51 in.)
G170A01A-GAT CHECKING BRAKE PEDAL FREE-PLAY 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 in resistance. 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 or repaired if necessary.
SSA6170A
3 ~ 8 mm (0.12 ~ 0.31 in.)
G150A01A-GAT CHECKING STEERING WHEEL FREEPLAY To check the steering wheel freeplay, stop the car with the wheels pointed straight ahead and gently move the steering wheel back and forth. Use very light finger pressure and be sensitive to changes in resistance that mark the limits of the freeplay. If the freeplay is greater than specified, have it inspected by your Hyundai dealer and adjusted or repaired if necessary.
G150A01HP
Maximum
30 mm (1.18 in)

DO-IT-YOURSELF MAINTENANCE
6-18
G200A01A-AAT CHECKING AND REPLACING FUSES Replacing a Fusible Link A fusible link will melt if the electrical circuits from the battery are ever overloaded, thus pre- venting damage to the entire wiring harness. (This could be caused by a short in the system drawing too much current.) If this ever happens, have a Hyundai dealer determine the cause, repair the system and replace the fusible link. The fusible links are located in a relay box for easy inspection.
G200A01HP
Bad
Good
Belt routing should also be checked to be sure there is no interference between the belts and other parts of the engine. After a belt is re- placed, the new belt should be adjusted again after two or three weeks to eliminate slack resulting from initial stretching after use.
G190A01A-GAT CHECKING DRIVE BELTS Drive belts should be checked periodically for proper tension and adjusted if necessary. At the same time, belts should be examined for cracks, wear, fraying or other evidence of deterioration and replaced if necessary. Diesel (2.5 TCI)
G190D01HP
G190D02HP
Gasoline
Generator pulley
Idler pulley Water pump pulley
COMP.pulley Autotensioner
Crankshaft pulley
Diesel (2.9 CRDi)
Crankshaft pulleyCOMP. pulley
Generator pulley Power steering pulley
Idler pulley Tension pulley
COMP. pulley
Power steering pulley
Water pump pulley Tension pulley Power steering pulley
Crankshaft pulleyTension pulleyGenerator pulley
Tension pulley
Tension pulley
G180A01A-GAT CHECKING BRAKE PEDAL CLEARANCE You need a helper to check the brake pedal clearance. With the engine running, have your helper press down on the brake pedal several times and then hold it down with a force of about 490N (50 kg, 110 lbs). The brake pedal clear- ance is the distance from the top surface of the brake pedal to the asphalt sheeting under the floor mat. If the brake pedal clearance is not within the limits specified in the illustration, have it inspected by your Hyundai dealer and adjust- ed or repaired if necessary.
SSA6180A
71 mm (2.80 in.)

VEHICLE SPECIFICATIONS 9-1
GASOLINE
MF 68 AH
120 A (13.5 V)
9. VEHICLE SPECIFICATIONS J010A01HP-GAT MEASUREMENT
Overall length Overall width Overall height Wheel baseWheel tread
Front Rear
Type Wheel free playOil pump type
Ball and nut, torsion bar type (Integral type)0 ~ 30 mm (0 ~ 1.18 in.) Vane type
J020A01HP-GAT POWER STEERING J030A01HP-GAT TIRE
Standard OptionSpare235/75 R15 255/65 R16
Full Size
J050A02HP-GAT BRAKE Dual hydraulic with brake booster Ventilated disc Disc type Disc type (with ABS)Drum type (without ABS) Cable operated on rear wheel
Type Front brake type Rear brake typeParking brake
J060A01Y-GAT FUEL SYSTEM
Fuel tank capacity75 liter mm (in.)
4710 (185.4) 1860 (73.2) 1795 (70.6) 2750 (108.2)1530 (60.2) 1530 (60.2)
ITEM Battery Alternator
J040A02HP-GAT ELECTRICAL
2.5 TCI
MF 90 AH
90 A (12 V)
9
2.9 CRDi
MF 100 AH
110 A (12 V)
DIESEL
E.C only Except E.C

VEHICLE SPECIFICATIONS
9-4 Oil & Grease Standard
HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4) DEXRON-II, DEXRON-IIIATF DEXRON-IIIHYPOID GEAR OIL API GL-5 or HIGHER,SAE 80W[BELOW -30°C(-22°F)]/90W[ABOVE -30°C(-22°F)]MITSUBISHI GENUINE GEAR OIL PART NO. 8149630EX orCASTROL HYPOY LS(2.5 TCI)MOBIL INFILREX 33 (2.9 CRDi or 3.5 V6)HYPOID GEAR OIL API GL-5 or HIGHER,SAE 80W[BELOW -30°C(-22°F)]/90W[ABOVE -30°C(-22°F)]Ethylene glycol base for aluminum radiatorPSF-3 TYPE FLUIDDOT 3, DOT 4 or Equivalent
Q’ty (liter)
2.5 (2.5 TCI), 3.2 (2.9 CRDi or 3.5 V6) 8.2 (2.5 TCI), 11.8 (2.9 CRDi ), 10.5 (3.5 V6)1.42Part-time 4WD:1.8Full-time 4WD: 1.3 NO.7:2.6, NO.7.5:2.88(2.5 TCI), 9(2.9 CRDi), 11(3.5 V6) 1.3As required
Item
Transmission fluid Transfer case oil Front axle gear oil Rear axle gear oil Coolant Power steering gear oilBrakes and clutch fluid
Manual Auto
With LSD Without LSD
J080A05HP-GAT LUBRICATION CHART

INDEX 10-1
A Air bag
................................................................................... 1-29 ~ 1-32
Air Cleaner Filter ............................................................................... 6-10
Air Conditioning Care .............................................................................................. 6-14
Operation .............................................................................. 1-72, 6-15
Switch ............................................................................................ 1-71
Air Filter (For Evaporator and Blower Uni t) ............................. 1-78, 6-15
Antenna ............................................................................................. 1-98
Ashtray .............................................................................................. 1-52
Audio Fault Code .............................................................................. 1-95
Automatic Heating and Cooling Control System ................... 1-73 ~ 1-77
BBattery ...................................................................................... 2-14, 6-18
Bi-Level Heating ................................................................................ 1-69
Brake
Anti-lock system .............................................................................. 2-8
Checking the brakes ..................................................................... 6-13
Fluid ............................................................................................... 6-13
Pedal clearance ............................................................................ 6-17
Pedal free-play .............................................................................. 6-17
Practices ....................................................................................... 2-12
Breaking-In your New Hyundai ........................................................... 1-2 CCare of Cass
ette Tapes ................................................................... 1-96
Care of Disc ...................................................................................... 1-96
Cassette Tape Player Operation (H240) ............................... 1-84 ~ 1-85
Cassette Tape Player Operation (H280) ............................... 1-89 ~ 1-90
Catalytic Con verte .............................................................................. 7-1
CD Auto changer (H280) ............................................. 1-59, 1-93 ~ 1-94
Child Restraint System .......................................................... 1-23 ~ 1-27
Child-Protector Rear Door Lock ......................................................... 1-7
Cigarette Lighter ................................................................................ 1-51
Clock ................................................................................................. 1-50
Clutch Checking fluid ................................................................................ 6-14
Pedal free-play .............................................................................. 6-17
Combination Light Headlight flasher ........................................................................... 1-48
Headlight switch ............................................................................ 1-48
High-beam switch .......................................................................... 1-48
Lane change signal ....................................................................... 1-47
Parking light auto cut .................................................................... 1-48
Turn signal operation .................................................................... 1-47
Compact Disc Player Operation (H280) ................................ 1-91 ~ 1-92
Cooling Fans ..................................................................................... 6-20
Corrosion protection
Cleaning the interior ........................................................................ 4-3
Protecting your Hyundai from corrosion ......................................... 4-1Washing and waxing ....................................................................... 4-2
Cruise Control ........................................................................ 1-64 ~ 1-66
10. INDEX
10

INDEX 10-3
High-Mounted Rear Stoplight ............................................................
1-61
Hood Release ................................................................................... 1-62
Horn .................................................................................................. 1-63
I
Ignition Switch ..................................................................................... 2-2Immobilizer System .................................................................... 1-3 ~ 1-6
Limp Home Procedures ....................................... 1-3 ~ 1-4, 1-5 ~ 1-6
Key ........................................................................................... 1-3, 1-4
Instrument Cluster and Indicator ............................................ 1-34 ~ 1-37
Instrument Panel Light Control (Rheostat) .......................................1-51
Instruments and Controls ............. ..................................................... 1-33
Intermittent Wiper .............................................................................. 1-49
JJump Starting ...................................................................................... 3-1
K
Key ...................................................................................................... 1-2 If you lose your keys .................................................................... 3-10
Positions .......................................................................................... 2-2
L
Light Bulbs Replacement ............. ..................................................... 6-23
Limited-Slip Differential ..................................................................... 2-12Luggage Compartment
Cargo Security Screen .................................................................. 1-60
Light ............................................................................................... 1-59
Net ................................................................................................. 1-59
MMaintenance Intervals Explanation of scheduled maintenance items ........................ 5-7 ~ 5-8
Maintenance under severe usage conditions ................................. 5-6
Scheduled maintenance ......................................................... 5-2 ~ 5-5
Service requirements ...................................................................... 5-1
Mirrors Day-night inside rearview ................................................... 1-57 ~ 1-58
Outside rear view .......................................................................... 1-55
Multimeter ............................................................................... 1-44 ~ 1-46
Altimeter ........................................................................................ 1-45
Azimuth compass .......................................................................... 1-44
Barometer ...................................................................................... 1-46
Digital Clock .................................................................................. 1-46
Relative altimeter ........................................................................... 1-45
OOdometer .......................................................................................... 1-43
PParking Brake ................................................................................... 1-58
Part-time 4WD Operation ......................................................... 2-9 ~ 2-10
Power Driver's Seat .......................................................................... 1-13