engine Hyundai Terracan 2003 Service Manual

DRIVING YOUR HYUNDAI
2- 14 C160C01A-AAT Use High Quality Ethylene Glycol Coolant Your Hyundai is delivered with high quality ethyl- ene glycol coolant in the cooling system. It is the only type of coolant that should be used because it helps prevent corrosion in the cooling system, lubricates the water pump and prevents freezing. Be sure to replace or replenish your coolant in accordance with the maintenance schedule in Section 5. Before winter, have your coolant test- ed to assure that its freezing point is sufficient for the temperatures anticipated during the winter. C160D01A-AAT Check Battery and Cables Winter puts additional burdens on the battery system. Visually inspect the battery and cables as described in Section 6. The level of charge in your battery can be checked by your Hyundai dealer or a service station. C160E01A-AAT Change to "Winter Weight" Oil if Necessary In some climates it is recommended that a lower viscosity "winter weight" oil be used during cold weather. See Section 9 for recommendations. If you aren’t sure what weight oil you should use, consult your Hyundai dealer.
o Remember, your Hyundai does not require
extended warm-up. As soon as the engine is running smoothly, you can drive away. In very cold weather, however, give your engine a slightly longer warm-up period.
o Don't "lug" or "over-rev" the engine. Lugging is driving too slowly in too high a gear result- ing in the engine bucking. If this happens, shift to a lower gear. Over-revving is racing the engine beyond its safe limit. This can be avoided by shifting at the recommended speeds.
o Use your air conditioning sparingly. The air
conditioning system is operated by engine power so your fuel economy is reduced when you use it.
C160A01A-AAT WINTER DRIVING The more severe weather conditions of winter result in greater wear and other problems. To minimize the problems of winter driving, you should follow these suggestions:
C150A01A-AAT SMOOTH CORNERING Avoid braking or gear changing in corners, espe- cially when roads are wet. Ideally, corners should always be taken under gentle acceleration. If you follow these suggestions, tire wear will be held to a minimum. C160B01A-GAT Snowy or Icy Conditions To drive your vehicle in deep snow, it may be necessary to use snow tires or to install tire chains on your tires. If snow tires are needed, it is necessary to select tires equivalent in size and type of the original equipment tires. Failure to do so may adversely affect the safety and handling of your car. Furthermore, speeding, rapid accel- eration, sudden brake applications, and sharp turns are potentially very hazardous practices. During deceleration, use engine braking to the fullest extent. Sudden brake applications on snowy or icy roads may cause skids to occur. You need to keep sufficient distance between the vehicle in operation in front and your vehicle. Also, apply the brake gently. It should be noted that installing tire chains on the tire will provide a greater driving force, but will not prevent side skids. NOTE: Tire chains are not legal in all provinces. Check province laws before fitting tire chains.

DRIVING YOUR HYUNDAI 2- 15
C160H01A-AAT Use Approved Anti-Freeze in Window Washer System To keep the water in the window washer system from freezing, add an approved anti-freeze solu- tion in accordance with instructions on the con- tainer. Window washer anti-freeze is available from Hyundai dealers and most auto parts out- lets. Do not use engine coolant or other types of anti-freeze as these may damage the finish.
C160F01A-AAT Check Spark Plugs and Ignition System Inspect your spark plugs as described in Section 6 and replace them if necessary. Also check all ignition wiring and components to be sure they are not cracked, worn or damaged in any way.
C160G02A-GAT To Keep Locks from Freezing To keep the locks from freezing, squirt an ap- proved de-icer fluid or glycerine into the key opening. If a lock is covered with ice, squirt it with an approved de-icing fluid to remove the ice. If the lock is frozen internally, you may be able to thaw it out by using a heated key. Handle the heated key with care to avoid
injury.
NOTE: The proper temperature for using the immo- bilizer key is from -40°C (-40°F) to 80°C (176°F). If you heat the immobilizer key over 80°C (176°F) to open the frozen lock, it may cause damage to the transponder in its head. C160I01HP-GAT Don’t Let Your Parking Brake Freeze Under some conditions your parking brake can freeze in the engaged position. This is most likely to happen when there is an accumulation of snow or ice around or near the rear brakes or if the brakes are wet. If there is a risk the parking brake may freeze, apply it only temporarily while you put the gear selector lever in "P" (automatic) or in first or reverse gear (manual transmission) and block the rear wheels so the car cannot roll. Then release the parking brake. C160K01A-AAT Carry Emergency Equipment Depending on the severity of the weather where you drive your car, you should carry appropriate emergency equipment. Some of the items you may want to carry include tire chains, tow straps or chains, flashlight, emergency flares, sand, a shovel, jumper cables, a window scraper, gloves, ground cloth, coveralls, a blanket, etc.
C160J01A-AAT Don’t Let Ice and Snow Accumulate Underneath Under some conditions, snow and ice can build up under the fenders and interfere with the steer- ing. When driving in severe winter conditions where this may happen, you should periodically check underneath the car to be sure the move- ment of the front wheels and the steering compo- nents is not obstructed.
C180A01A-AAT USE OF LIGHTS Check your lights regularly for correct operation and always keep them clean. When driving dur- ing the day in conditions of poor visibility, it is helpful to drive with headlights on low beam. This enables you to be seen as well as to see.
C170A01A-AAT HIGHER SPEED MOTORING Pre-Trip Inspections 1. Tires: Adjust the tire inflation pressures to specifica- tion. Low tire inflation pressures will result in overheating and possible failure of the tires. Avoid using worn or damaged tires which may result in reduced traction or tire failure. NOTE: Never exceed the maximum tire inflation pres- sure shown on the tires. 2. Fuel, engine coolant and engine oil: High speed travel consumes more fuel than urban motoring. Do not forget to check both engine coolant and engine oil. 3. Drive belt: A loose or damaged drive belt may result in overheating of the engine.

DRIVING YOUR HYUNDAI
2- 16 C190D01A-GAT Safety Chains Should the hitch connection between your car and the trailer or vehicle you are towing fail, the trailer or vehicle could wander dangerously across other lanes of traffic and ultimately collide with another vehicle. To eliminate this potentially dan- gerous situation, safety chains, attached be- tween your car and the trailer or towed vehicle, are required in most provinces. C190E02HP-GAT Trailer Weight Limit
Tongue load Total trailer weightSSA2200B
Tongue loads can be increased or decreased by re-distributing the load in the trailer. This can be verified by checking the total weight of the loaded trailer and then checking the load on the tongue.
C190A01HP-GAT TRAILER OR VEHICLE TOWING If you are considering towing with your car, you should first check with your Province Depart- ment of Motor Vehicles to determine their legal requirements. Since laws vary from province to province the requirements for towing trailers, cars, or other types of vehicles or apparatus may differ. Ask your Hyundai dealer for further details before towing. CAUTION: Do not do any towing with your car during its first 2,000 km (1,200 miles) in order to allow the engine to properly break in. Failure to heed this caution may result in serious en- gine or transmission damage. C190B01S-AAT Trailer HitchesSelect the proper hitch and ball combination, making sure that it’s location is compatible with that of the trailer or vehicle being towed. Use a quality non-equalizing hitch which distrib- utes the 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 HITCH DESIGNED FOR TEMPORARY INSTALLATION AND NEVER USE ONE THAT ATTACHES ONLY TO THE BUMPER. C190C02Y-GAT Trailer Brakes If your trailer is equipped with a braking system, make sure it conforms to federal and/or local regulations and that it is properly installed and operating correctly. NOTE: If you tow a trailer or vehicle, your car will require more frequent maintenance due to the additional load. See "Maintenance Under Severe Usage Conditions" on page 5-6. CAUTION:
o Never connect a trailer brake system di-
rectly to the vehicle brake system.
o When towing a trailer on steep grades (in excess of 12%) pay close attention to theengine coolant temperature gauge to en- sure the engine does not overheat. If the needle of the coolant temperature gauge moves across the dial towards "H" (HOT), pull over and stop as soon as it is safe to do so, and allow the engine to idle until it cools down. You may proceed once the engine has cooled sufficiently.

DRIVING YOUR HYUNDAI 2- 17
NOTE:
1. Never load the trailer with more weight in
the back than in the front. About 60% ofthe trailer load should be in the front half on the trailer and the remaining 40% in the rear.
2. The total gross vehicle weight with trailer
must not exceed the Gross Vehicle Weight Rating (GVWR) shown on the vehicle iden- tification plate (see page 8-1). The total gross vehicle weight is the combined weight of the vehicle, driver, all passen- gers and their luggage, cargo, hitch, trailer tongue load and other optional equip- ment.
3. The front or rear mission weight must not exceed the Gross Axle Weight Rating (GAWR) shown on the vehicle identifica- tion plate (see page 8-1). It is possible that your towing package does not exceed the GVWR but exceeds the GAWR. Improper trailer loading and/or too much luggage in the cargo area can overload the rear mis- sion. Redistribute the load and check the mission weight again.
4. The maximum permissible static vertical load on the coupling device is : 5. The maximum permissible overhang of
the coupling point is 1,230 mm.
Gross axle weight Gross vehicle weightSSA2200D
C190E01HP
CAUTION: The following specifications are recom- mended when towing a trailer. The loaded trailer weight cannot safely exceed the val- ues in the following chart.
Spare tire
2.9, 3.5 E.C only Except E.C Load
75 kg
115 kg 75 kg
Engine 2.5
Coupling point
C190F01HP-GAT Trailer or Vehicle Towing Tips
1. Before towing, check hitch and safety chain connections as well as proper operation of the trailer running lights, brake lights, and turn
signals.
2. Always drive your vehicle at a moderate speed (Less than 100 km/h).
3. Trailer towing requires more fuel than normal conditions.
4. To maintain engine braking efficiency, do not tow a trailer with transmission in fifth gear(manual transmission) or an overdrive gear (automatic transmission).
WARNING:
o Improperly loading your car and trailer
can seriously affect its steering and brak-ing performance causing a crash which could cause injury or death.
o When a trailer is used, the operation speed is restricted to 100km/h or less. Engine
2.5
2.5, 2.9, 3.5
2.9 E.C only
3.5 Except E.C
kg (Lbs.)
Maximum Towable Weight
With Brake Without Brake Trailer
1800(3,968) 2800(6,173) 1800(3,968)
700(1,543) Tongue
75 (165)
115(254) 75(165)
28(61.7)

DRIVING YOUR HYUNDAI
2- 18
5. Always secure items in the trailer to prevent
load shift while driving.
6. Check the condition and air pressure of all
tires on the trailer and your car. Low tire pressure can seriously affect the handling.
Also check the spare tire.
7. The vehicle/trailer combination is more af-
fected by crosswind and buffeting. When being passed by a large vehicle, keep a constant speed and steer straight ahead. If there is too much wind buffeting slow down to get out of the other vehicle's air turbulence.
8. When parking your car and trailer, especially
on a hill, be sure to follow all the normal precautions. Turn your front wheel into the curb, set the parking brake firmly, and put the transmission in 1st or Reverse (manual) or Park (automatic). In addition, place wheel
chocks at each of the trailer's tires.
9. If the trailer has electric brakes, start your vehicle and trailer moving, and then apply the trailer brake controller by hand to be sure the brakes are working. This lets you check your
electrical connection at the same time.
10. During your trip, check occasionally to be
sure that the load is secure, and that the lights and any trailer brakes are still working.
11. Avoid jerky starts, sudden acceleration or sudden stops.
12. Avoid sharp turns and rapid lane changes.
13. Avoid holding the brake pedal down too long or too frequently. This could cause the brakes to overheat, resulting in reduced braking effi- ciency.
14. When going down a hill, shift into a lower gear
and use the engine braking effect. When ascending a long grade, downshift the trans- mission to a lower gear and reduce speed to reduce chances of engine overloading and/or overheating.
15. If you have to stop while going uphill, do not
hold the vehicle in place by pressing on the accelerator. This can cause the automatic transmission to overheat. Use the parking brake or footbrake.
NOTE: When towing, check transmission fluid more frequently. CAUTION: If overheating should occur when towing, (temperature gauge reads near red zone), taking the following action may reduce or
eliminate the problem.
1. Turn off the air conditioner.
2. Reduce highway speed.
3. Select a lower gear when going uphill.
4. While in stop and go traffic, place the gear selector in park or neutral and idle theengine at a higher speed.

WHAT TO DO IN AN EMERGENCY 3-1
3. WHAT TO DO IN ANEMERGENCY
D010A01A-AAT IF THE ENGINE WILL NOT START WARNING: If the engine will not start, do not push or pull the car to start it. This could result in a collision or cause other damage. In addition, push or pull starting may cause the catalytic converter to be overloaded and create a fire hazard. D010B01HP-GAT If Engine Doesn’t Turn Over or Turns Over Slowly
1. If your car has an automatic transmission, be sure the gear selector lever is in "N" or "P" and the emergency brake is set. 2. Check the battery connections to be sure
they are clean and tight.
3. Turn on the interior light. If the light dims or
goes out when you operate the starter, the battery is discharged.
4. Check the starter connections to be sure they are securely tightened.
5. Do not push or pull the vehicle to start it. See instructions for "Jump Starting". D020A02A-AAT JUMP STARTING WARNING: The gas produced by the battery during the jump-start operation is highly explosive. If these instructions are not followed exactly, serious personal injury and damage to the vehicle may occur! If you are not sure how to follow this procedure, seek qualified assis- tance. Automobile batteries contain sulfuric acid. This is poisonous and highly corrosive. When jump starting, wear protective glasses and be careful not to get acid on yourself, your clothing or on the car.
o If you should accidentally get acid on your
skin or in your eyes, immediately remove any contaminated clothing and flush the area with clear water for at least 15 minutes. Then promptly obtain medical attention. If you must be transported to an emergency facility, con-
D010C01Y-AAT If Engine Turns Over Normally but Does Not Start
1. Check fuel level.
2. With the key in the "OFF" position, check all
connectors at ignition coils and spark plugs.Reconnect any that may be disconnected or loose.
3. Check the fuel line in the engine room.
4. If engine still refuses to start, call a Hyundai dealer or seek other qualified assistance.
D010D01A-AAT If Engine Stalls While Driving
1. Reduce your speed gradually, keeping a straight line. Move cautiously off the road to a safe place.
2. Turn on your emergency flashers.
3. Try to start the engine again. If your vehicle will not start, contact a Hyundai dealer or seekother qualified assistance.
AX30030A
Negative to the engine not to the battery
Positive to positive
Booster battery
c
e
f d
Discharged battery
D010B01HP
3

WHAT TO DO IN AN EMERGENCY
3-2 tinue to apply water to the affected area with a sponge or cloth.
o The gas produced by the battery during the
jump-start operation is highly explosive. Do not smoke or allow a spark or an open flame in the vicinity.
o The battery being used to provide the jump
start must be 12-volt. If you cannot determine that it is a 12-volt battery, do not attempt to use it for the jump start.
o To jump start a car with a discharged battery,
follow this procedure exactly:
1. If the booster battery is installed in another vehicle, be sure the two vehicles are nottouching.
2. Turn off all unnecessary lights and acces-
sories in both vehicles.
3. Attach the clamps of the jumper cable in the
exact location shown in the illustration. First, attach one clamp of the jumper cable to the positive (+) post or cable of the discharged battery. Then attach the other end of the same cable to the positive (+) post or cable of the booster battery. Next, using the other cable, attach one clamp to the negative (-) post or cable of the booster battery. Then attach the other end of that cable to a solid metal part of the engine away from the battery. Do not connect the cable to any moving part.
4. Start the engine in the car with the booster battery and let it run for a few minutes. This will help to assure that the booster battery is fully charged. During the jumping operation,run the engine in this vehicle at about 2000 rpm.
5. Start the engine in the car with the discharged battery using the normal starting procedure. After the engine starts, leave the jumper cables connected and let the engine run at fast idle or about 2000 rpm for several min- utes.
6. Carefully remove the jumper cables in the reverse order of attachment.
If you do not know why your battery became discharged (because the lights were left on, etc.), have the charging system checked by your Hyundai dealer. visible loss of coolant and no steam, leave theengine running and check to be sure the engine cooling fan is operating. If the fan is not running, turn the engine off.
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 satis- factory, check for engine coolant leaking from the radiator, hoses or under the car. (If the air conditioning had been in use, it is normal for cold water to be draining from it when you stop).
WARNING: While the engine is running, keep hands and clothing away from moving parts such as the fan and drive belts to prevent injury.
5. If the water pump drive belt is broken or coolant is leaking out, stop the engine im- mediately and call the nearest Hyundai deal- er for assistance.
WARNING: Do not remove the radiator cap when the engine is hot. This can allow coolant to be blown out of the opening and cause serious burns.
6. If you cannot find the cause of the overheat- ing, wait until the engine temperature has returned to normal. Then, if coolant has been lost, carefully add coolant to the reservoir (Page 6-8) to bring the fluid level in the reser- voir up to the halfway mark.
D030A01HP-AAT IF THE ENGINE OVERHEATS If your temperature gauge indicates overheating, you experience a loss of power, or hear loud pinging or knocking, 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" (auto- matic), 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 under the car or steam is coming out from under the hood, stop the engine. Do not open the hood until the engine coolant has stopped running or the steaming has stopped. If there is no

WHAT TO DO IN AN EMERGENCY
3-10 D120A01A-GAT IF YOU LOSE YOUR KEYS If you lose your keys, many Hyundai dealers can make you a new key if you have your key number. If you lock the keys inside your car and you cannot obtain a new key, many Hyundai dealers can use special tools to open the door for you. Information about the key of immobilizer system (if installed) will be found on page 1-2.
D080D01O-GAT Emergency Towing
D080D01HP For emergency towing when no commercial tow vehicle is available, attach a tow cable, chain or strap to one of the tie-down hooks under the front of your car. Be very careful when attempting this procedure when the vehicle is on any unpaved surface to avoid damage to your vehicle. Nor should towing be attempted if the wheels, drive train, axles, steering or brakes are dam- aged. Before towing, be sure the transmission is in neutral and the key is in "ACC" (with the engine off) or in the "ON" position (with the engine running). A driver must be in the towed car to steer it and operate the brakes. NOTE: To avoid serious damage to your 4WD ve- hicle, limit the towing to 15 km/h (10 mph) and not for more than 1.5 km (1 mile) at ANY TIME.
o OK for 4WD
o OK for Automatic or Manual Transmission
Equipped VehicleD080C02HP
NOTE: Before towing, check the level of the trans- mission fluid. If it is below the "HOT" range on the dipstick, add fluid. If you cannot add fluid, a towing dolly must be used.
D080C01HP-GAT Towing A Car With Automatic Trans- mission
CAUTION: A car with an automatic transmission should never be towed from the front with the rear wheels on the ground. This can cause seri- ous damage to the transmission. If the car must be towed from the front, a towing dolly must be used under the rear wheels.
o If the car is being towed with all four wheels on the ground, it can be towed only from the front. Be sure that the transmission is in neutral. Do not tow at speeds greater than 50 km/h (30 mph) and for more than 25 km (15 miles).
Be sure the steering is unlocked by placing the key in the "ACC" position. A driver must be in the towed vehicle to operate the steering and brakes.
o Not OK for 4WD (OK for Part Time 4WD in 2H Position)
o OK for Automatic or Manual Transmission
Equipped Vehicle with No Damage
D080C01HP

VEHICLE MAINTENANCE REQUIREMENTS 5-1
F010C01HP-GAT Specified Scheduled ProceduresThese are the procedures such as inspections, adjustments and replacements that are listed in the maintenance charts starting on page 5-2. These procedures must be performed at the intervals shown in the maintenance schedule to assure that your warranty remains in effect. Although it is strongly recommended that they be performed by the factory-trained or distribu- tor-trained technicians at your Hyundai dealer, these procedures may be performed at any qualified service facility. It is suggested that genuine Hyundai service parts be used for any required repairs or re- placements. Other parts of equivalent quality such as engine oil, engine coolant, manual or auto transmission oil, brake fluid and so on which are not supplied by Hyundai Motor Com- pany or its distributor may be used without affecting your warranty coverage but you should always be sure these are equivalent to the quality of the original Hyundai parts. Your Ser- vice Passport provides further information about your warranty coverage.
5. VEHICLE
MAINTENANCE
REQUIREMENTS F010E01A-AAT Do-It-Yourself Maintenance If you are mechanically inclined, own a few tools that are required and want to take the time to do so, you can inspect and service a number of items. For more information about doing it your- self, see Section 6.
F010D01A-AAT General ChecksThese are the regular checks you should per- form when you drive your Hyundai or you fill the fuel tank. A list of these items will be found on page 6-4.
F010A01A-GAT MAINTENANCE INTERVALS Service Requirements To assure that you receive the greatest number of kilometers of satisfying operation from your Hyundai, certain maintenance procedures must be performed. Although careful design and en- gineering have reduced these to a minimum, those that are required are of the utmost impor- tance. It is your responsibility to have these mainte-nance procedures performed to comply with the terms of the warranties covering your new Hyundai. The Service Passport supplied with your new vehicle provides further information about these warranties. F010B01A-AAT Maintenance RequirementsThe maintenance required for your Hyundai can be divided into three main areas: o Specified scheduled procedures o General checks o Do-it-yourself maintenance F010F01A-AAT A Few Tips
o Whenever you have your Hyundai serviced,
keep copies of the service records in your glove box. This will help ensure that you can document that the required procedures have been performed to keep your warranties in effect. This is especially important when service is not performed by an authorized Hyundai dealer.
o If you choose to do your own maintenance
and repairs, you may find it helpful to havean official Hyundai Shop Manual. A copy of this publication may be purchased at your Hyundai dealer's parts department.
F020A01Y-GAT SCHEDULED MAINTENANCE RE- QUIREMENTS Inspection should be performed any time a malfunction is experienced or suspected. Re- ceipts for all emission control system services should be retained to demonstrate compliance with conditions of the emissions system war- ranty. For severe usage maintenance requirements, see page 5-6 of this section.
5

VEHICLE MAINTENANCE REQUIREMENTS
5- 2
F030A01A-GAT SCHEDULED MAINTENANCE The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for all vehi
cle services to protect
your warranty. Where both mileage and time are shown, the frequency of service is determined by whichever occurs first. F030B01HP-GAT R :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.
ENGINE CONTROL SYSTEM MAINTENANCE (GASOLINE)
ENGINE OIL AND FILTER See Note (1)DRIVE BELT (ALT, DAMPER, TENSIONER, IDLER)FUEL FILTER (MFI TYPE)FUEL LINES, FUEL HOSES AND CONNECTIONSTIMING BELTVAPOR HOSE AND FUEL FILLER CAPVACUUM AND CRANKCASE VENTILATION HOSESAIR CLEANER FILTERSPARK PLUGSSPARK PLUGS (PLATINUM COATED)
NO. DESCRIPTION
1 2 3 4 5 6 7 8 9 120
96
RRR I I I
R I105
84
R I I I90 72
R I I
R I I
RRR75 60
R I I I I60 48
R I
R I III
R45 36
R I I I
R30 24
R I II I
R I
15 12
R I I IKILOMETERS X 1000 MONTHS
Note: (1) European Community Only - API SG, SG/CD, SH OR SH/CD Except European Community - API SE OR ABOVE In case of Gasoline standard engine as recommended oil (API SE or ABOVE) is difficult to obtain in fieId, following oil recomen ded:
API SD - The engine oil and filter should be changed at every 10,000km or 6 months.