light Hyundai Terracan 2003 Workshop Manual

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 6-19
AXA6201B
3. Be sure to check all other fuses even if you find one that appears to have burned out.
4. Replace the blown fuse by pressing a new fuse of the same rating into place. The fuse should be a snug fit. If it is not, have the fuse clip repaired or replaced by a Hyundai dealer. If you do not have a spare fuse, you may be able to borrow a fuse of the same or lower rating from an accessory you can tempo- rarily get along without (the radio or cigarette lighter, for example). Always remember to replace the borrowed fuse.
1. Turn off the ignition and all other switches.
2. Open the fuse box and examine each fuse.
Remove each fuse by pulling it toward you (a small "fuse puller" tool is contained in the relay box to simplify this operation).
Good
G200B03YBurned out
CAUTION: A burned-out fuse indicates that there is a problem in the electrical circuit. If you re- place a fuse and it blows as soon as the accessory is turned on, the problem is seri- ous and should be referred to a Hyundai dealer for diagnosis and repair. Never re- place a fuse with anything except a fuse with the same or a lower amperage rating. A higher capacity fuse could cause damage and create a fire hazard.
G200B01HP-GAT Replacing Accessory Fuse
G200B01HP
The fuse box for the lights and other electrical accessories will be found under the dashboard on the driver’s side. Inside the box you will find a list showing the circuits protected by each fuse.If any of your car’s lights or other electrical accessories stop working, a blown fuse could be the reason. If the fuse has burned out, you will see that the metal strip inside the fuse has burned through. If you suspect a blown fuse, follow this procedure:
CAUTION: When replacing a fusible link, never useanything but a new fusible link with the same or lower amperage rating. Never use a piece of wire or a higher-rated fusible link. This could result in serious damage and create a fire hazard.

DO-IT-YOURSELF MAINTENANCE
6-20
G220B01A-AAT Checking Engine Cooling FanThe engine coolant fan should come on auto- matically if the engine coolant temperature is high. G220C01A-AAT Checking Condenser Cooling FanThe condenser coolant fan should come on automatically whenever the air conditioning is in operation. G230A03A-AAT POWER STEERING FLUID LEVEL
G230A01HP
Gasoline or Diesel (2.5 TCI)
o Charge batteries only in a well ventilated
area.
o Do not permit flames, sparks or smoking in the area.
o Keep children away from the area. G210B01A-AAT Checking the BatteryKeep the battery clean. Any evidence of corro- sion around the battery posts or terminals should be removed using a solution of household bak- ing soda and warm water. After the battery terminals are dry, cover them with a light coat- ing of grease. G220A01A-AAT CHECKING ELECTRIC COOLING FANS 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 coolant 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.
G210A01A-AAT CHECKING THE BATTERYWARNING: Batteries can be dangerous! When working with batteries, carefully observe the follow- ing precautions to avoid serious injuries. The fluid in the battery contains a strong solu- tion of sulfuric acid, which is poisonous and highly corrosive. Be careful not to spill it on yourself or the car. If you do spill battery fluid on yourself, immediately do the following:
o If battery fluid is on your skin, flush the
affected areas with water for at least 15 minutes and then seek medical assistance.
o If battery fluid is in your eyes, rinse out your eyes with water and get medical assistanceas soon as possible. While you are being driven to get medical assistance, continue to rinse your eyes by using a sponge or soft cloth saturated with water.
o If you swallow battery fluid, drink a large quantity of water or milk followed by milk ofmagnesia, eat a raw egg or drink vegetable oil. Get medical assistance as soon as possible.
While batteries are being charged (either by a battery charger or by the vehicle’s alternator), they produce explosive gases. Always observe these warnings to prevent injuries from occur- ring:

DO-IT-YOURSELF MAINTENANCE 6-23
G260A01HP-GAT REPLACING HEADLIGHT BULBSBefore attempting to replace a headlight bulb, be sure the switch is turned to the "OFF" position. The next paragraph shows how to reach theheadlight bulbs so they may be changed. Be sure to replace the burned-out bulb with one of the same number and wattage rating.
WARNING:Be sure to carefully wipe away any waterdrained out in this manner, because the fuel mixed in the water might be ignited and result in a fire. NOTE: The driver's side headlight bulb can be changed after lifting the engine coolant res- ervoir by hand. CAUTION: Keep the lamps out of contact with petro-leum product, such as oil, gasoline, etc.
G260A01HP
Replacement instructions:
1. Allow the bulb to cool. Wear eye protection.
2. Always grasp the bulb by its plastic base,
avoid touching the glass.
3. Disconnect the power cord from the bulb base in the back of the headlight.
4. Push the bulb spring for removing the head-
light bulb.
5. Remove the protective cap from the re- placement bulb and install the new bulb bymatching the plastic base with the headlight hole. Retighten the bulb spring and recon- nect the power cord.
6. Use the protective cap and carton to dis- pose of the old bulb.
7. Check for proper headlight aim. G270A02Y-AAT HEADLIGHT BULB
G270A01HP
G300B01HP-GAT REMOVAL OF WATER FROM THE FUEL FILTER
(FOR DIESEL ENGINE (2.9 CRDi))
G300A01HP
If the fuel filter warning lamp illuminates during driving, it indicates that water has accumulated in the fuel filter. If this occurs, remove the water as described below.
1. Loosen the drain plug at the bottom of the fuel filter.
2. Tighten the drain plug when water no longer
comes out.
3. Check to be sure that the warning lamp illuminates when the ignition key is turned to "ON", and that it goes off when the engine is started. If in doubt, consult your nearest authorizedHYUNDAI dealer.

DO-IT-YOURSELF MAINTENANCE
6-24 6. Draw the vertical line (through the center of
each headlight) and the horizontal line (through the center of each headlight) on the aiming screen.
(1) Horizontal line dimension from ground :Low Beam : 894 mm (35.1 in.)
High Beam : 839 mm (33 in.)
(2) Distance between each vertical line : Low Beam : 1,316 mm (51.8 in.)
High Beam : 1,076 mm (42.4 in.)
And then, draw a parallel line at 38 mm (1.50 in.) under the horizontal line in case of adjusting the low beam or at 21 mm (0.83 in.) under the horizontal line in case of adjusting the high beam.
7. Adjust each cut-off line of the low beam to the parallel line with a phillips screwdriver - VERTICAL AIMING.
8. Adjust each cut-off line of the low beam to
the each vertical line with a phillips screw-driver - HORIZONTAL AIMING.
G290A01HP-GAT
HEADLIGHT AIMING ADJUSTMENT
G290A01HP
Horizontal aiming (Low Beam)
Vertical aiming (Low Beam)
Before performing aiming adjustment, make sure of the following.
1. Keep all tires inflated to the correct pres- sure.
2. Place the vehicle on level ground and press the front bumper & rear bumper down sev-eral times. Place vehicle at a distance of 3m (118.1 in.) from the test wall.
3. See that the vehicle is unloaded (except for
full levels of coolant, engine oil and fuel, andspare tire, jack, and tools). Have the driver or equivalent weight placed in driver's seat.
4. Clean the headlight lens and turn on the headlight.
5. Open the hood. Vertical aiming (High Beam)
Horizontal aiming(High Beam)
G270A02HP
WARNING: The halogen bulb contains gas under pres- sure and if impacted could shatter, resulting in flying fragments. Always wear eye pro- tection when servicing the bulb. Protect the bulb against abrasions or scratches and against liquids when lighted. Turn the bulb on only when installing in a headlight. Re- place the headlight if damaged or cracked. Keep the bulb out of the reach of children and dispose of the used bulb with care.

DO-IT-YOURSELF MAINTENANCE 6-25
If the vehicle has had front body repair and the headlight assembly has been replaced, the headlight aiming should be checked using an aiming screen as shown in the illustration. Turn on the headlight switch. (Low Beam or High Beam Position).
1. Adjust headlights so that main axis of light is parallel to center line of the body and is aligned with point "P" shown in the illustra- tion.
2. Dotted lines in the illustration show the cen- ter of headlights. "H" Horizontal center line of headlights fromground :Low Beam : 894 mm (35.1 in.) High Beam : 839 mm (33 in.) "W" Distance between each headlight center :Low Beam : 1,316 mm (51.8 in.)High Beam : 1,076 mm (42.4 in.) "L" Distance between the headlights and thewall that the lights are tested against :Low Beam : 3,000 mm (118.11 in.)High Beam : 3,000 mm (118.11in.)
G290B02HP
Vertical line
Cut-off line Ground line
L W
H
H "P"
21 mm ( 0.83 in.)

Horizontal line 39 mm (1.54 in.)
Vertical line
Cut-off line Ground line
L W
H
H "P"
38 mm ( 1.5 in.)
14 mm (0.55 in.)Horizontal line
G290B01HP-GAT Adjustment After Headlight Assembly Replacement
G290B01HP

DO-IT-YOURSELF MAINTENANCE
6-26 No.
9
10 11 12 Wattage
16 40
21/5 2121 215
G280A01HP-GAT
No.
1 2 345 6 78 Part Name
Head Light (Low/High) Turn Signal Light
Front Position LightRoom LightMap Light Front Fog Light Side RepeaterFront Door Edge Warning Light (If installed) Part Name
High Mounted Rear Stop Light (If installed) Luggage Compartment Light Rear Combination LightStop/Tail LightTurn Signal Light Back-up Light Rear Fog Light (If installed)License Plate LightWattage 55/55 215
10
8
55 5 5
G280A01HP
532
87611
910
1
4
12

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
10-2
D Defrosting/Defogging
......................................................................... 1-70
Door
Locking, unlocking front door with a key ........................................ 1-6
Drink Holder ...................................................................................... 1-52
Drive Belts ............................................................................... 6-15, 6-18
Driving
Driving for economy ...................................................................... 2-13
Smooth cornering .......................................................................... 2-14
Winter driving ................................................................................ 2-14
E
Emission Control System ................................................................... 7-1
Engine
Before starting the engine ............................................................... 2-2
Compartment (3.5 V6) ..................................................................... 6-1
Compartment (2.5 TCI) ................................................................... 6-2
Compartment (2.9 CRDi) ................................................................ 6-3
Coolant ............................................................................................ 6-7
Coolant temperature gauge ........................................................... 1-42
If the engine overheats ................................................................... 3-2
Number ............................................................................................ 8-1
Oil .................................................................................................... 6-4Starting ............................................................................................ 2-3
Engine Exhaust Can Be Dangerous ................................................... 2-1
FFan Speed Control ................................................................... 1-66, 1-75 Fog Light
Front .............................................................................................. 1-47
Rear .............................................................................................. 1-47
Front Seats Adjustable front seats ................................................................... 1-11
Adjustable headrests ..................................................................... 1-12
Adjusting seat forward and rearward ............................................1-11
Adjusting seatback angle .............................................................. 1-11
Fuel Capacity .......................................................................................... 9-1
Gauge ............................................................................................ 1-42
Unleaded gasoline ........................................................................... 1-1
Fuel Filler Lid Remote release ............................................................................. 1-61
Full-time 4WD Operation ....................................................... 2-10 ~ 2-12
Fuses ................................................................................................ 6-18
GGeneral Checks .................................................................................. 6-4
Glove Box ......................................................................................... 1-55
HHazard Warning System ................................................................... 1-50
Headlight Aiming Adjustment ............................................................ 6-24
Headlight Leveling Device System ...................................................1-64
Heating and Ventilation Air flow control ......................................................... 1-67 ~ 1-68, 1-76
Temperature control ...................................................................... 1-68

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