run Hyundai Terracan 2003 Workshop Manual

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
6-14
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
6-16 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
6-18 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

OWNER MAINTENANCE 6-19
The power steering fluid level should be checked
regularly.
To check the power steering fluid level, be sure
the ignition is "OFF", then check to make cer- tain that the power steering fluid level is be-tween the "MAX" and "MIN" level markings onthe fluid reservoir.
YG220A1-E
POWER STEERING HOSES
It is suggested that you check the power steer-
ing hose connections for fluid leakage at thoseintervals specified in the vehicle maintenanceschedule in Section 5. The power steering hosesshould be replaced if there are severe surfacecracking, pulling, scuffing or worn spots. Dete-rioration of the hoses could cause prematurefailure.
NOTE: The power steering pump may be noisy
when the engine is first started in the ex- treme cold (-4°F). This noise is not abnormaland will stop as the engine warms up. If thepower steering pump continues to be noisyafter the engine has warmed up, have itinspected by your Authorized HyundaiDealer. G230A03A-EAT POWER STEERING FLUID LEVEL
G230A01HP
G230A02HP
Petrol Engine
Diesel Engine
G350B01HP-GAT
BLEEDING THE FUEL SYSTEM (FOR DIESEL ENGINE)
The fuel system should be bled to remove air as
described in the illustration if the fuel supply is exhausted during travel, when the fuel filter isreplaced, or if the vehicle is not used for a longtime.
G350A01HP
NOTE: Do not check whilst the engine is running.
Do not start when power steering fluid res- ervoir is empty. Fluid Recommendation
Only automatic transmission fluid meeting the
specification of PSF-3 or ATF DEXRON 2 should be used in the power steering system.

EMISSION CONTROL SYSTEMS 7-1
vehicle may be damaged. You should inspect the exhaust system each time the car is raisedfor lubrication or oil change. To check condition
1. Holes and gas leaks due to corrosion, dam-
age, etc., should be rectified.
2. The joints should be checked for loose con- nections and gas leakage.
3. The hanger rubber and brackets should be checked for damage. DH010B1-E
1. CRANKCASE EMISSION CONTROL
SYSTEM ; For a Petrol Engine
The positive crankcase ventilation system is
employed to prevent air pollution caused by blow-by gases being emitted from the crank-case.
This system supplies fresh air to the crankcase
through the air cleaner. Inside the crankcase,the fresh air mixes with blow-by gases, thenpasses through the PCV valve into the intakesystem.
ZH010C1-E
2. EVAPORATIVE EMISSION CON-
TROL SYSTEM ; For a Petrol Engine
The Evaporative Emission Control System is designed to prevent fuel vapors from escapinginto the atmosphere.
Canister While the engine is inoperative, fuel vaporsgenerated inside the fuel tank are absorbed andstored in the canister. When the engine isrunning, the fuel vapors absorbed in the canis-ter are drawn into the induction system throughthe purge control solenoid valve.
YH000A1-A
7. EMISSION CON-
TROL SYSTEMS
YH020A1-E
EXHAUST GAS WARNING
Exhaust gases contain carbon monoxide, a
potentially toxic gas that is colorless and odor-less. Avoid breathing exhaust gases.
o Do not run the engine in confined areas, such as garages, any longer than neces- sary to move the car in or out.
o Do not drive with the trunk open. An open trunk may draw exhaust gases into the pas-senger compartment. If you must drive withthe trunk open, drive only with all the win-dows wide open and the blower motor onhigh speed.
o If it is necessary to sit in a parked car with the engine running for more than a shortperiod, adjust your heating system to forceoutside air into the car by placing the airselector button of the heater in the FRESHAIR position and mode control in the VENTposition. Set the fan at high speed and thecontrols in any position desired.
Inspect the exhaust system Whenever a change is noticed in the sound of
the exhaust system, the underside or rear of the ZH010A1-E EMISSION CONTROL SYSTEMS (Not all models) Your Hyundai is equipped with an emission control systems. There are three emission control systems which are as follows. (1) Crankcase emission control system (2) Evaporative emission control system(3) Exhaust emission control system In order to assure the proper function of the emission control system, it is recommendedthat you have your car inspected and main-tained by an authorized Hyundai dealer in ac-cordance with the schedule in this manual.
7

EMISSION CONTROL SYSTEMS
7-2
Purge Control Solenoid Valve
The purge control solenoid valve is controlled
by the ECU; when the engine coolant tempera- ture is low, and during idling, it closes, so thatevaporated fuel is not taken into the surge tank.After engine warm-up, during ordinary driving, itopens to introduce evaporated fuel to the surgetank. misfire and result in excessive loading of thecatalytic converter.
o Avoid idling the engine for periods longer than 10 minutes.
o Your Hyundai should not be either pushed or pulled to get it started. This can cause thecatalytic converter to overload.
o Take care not to stop your Hyundai over any combustible material such as grass, paper,leaves or rags.
o Do not touch the catalytic converter or any other part of the exhaust system while theengine is running.
o Remember that your Hyundai dealer is your best source of assistance.
JH010D1-E
3. EXHAUST EMISSION CONTROL
SYSTEM
EGR system ; For a Petrol Engine This system helps control oxides of nitrogen byrecirculating a portion of the exhaust gases intothe intake manifold, thereby reducing cylindercombustion temperatures. YH040A2-E
CATALYTIC CONVERTER
; For a Petrol Engine The catalytic converter is part of the exhaust emission control system. Its purpose is to re-move certain engine emission products fromthe engine's exhaust. It looks something like amuffler and is located underneath the car in theexhaust system. YH040B1-E
About the Catalytic Converter ; For a Petrol Engine
Exhaust gases passing through the catalytic converter cause it to operate at very high tem-peratures. As a result, the introduction of largeamounts of unburned petrol may cause it tooverheat and create a fire hazard. This can beavoided by observing the following:
o Use only unleaded fuel.
o Maintain your engine in good condition. Ex- tremely high converter temperatures can re- sult from improper operation of the electri-cal, ignition or M.P.I. system.
o If your engine stalls, pings, knocks, or is hard to start, take your car to your Hyundaidealer as soon as possible and have thedifficulty corrected.
o Avoid driving with a very low fuel level. If you run out of petrol, it could cause the engine to H020D01S-GAT CATALYTIC CONVERTER ; For a Diesel Engine All Hyundai vehicles are equipped with oxida- tion type catalytic converter to reduce the car-bon monoxide, hydrocarbons and particulatecontained in the exhaust gas. H020C01HP-EAT EGR SYSTEM ; For a Diesel Engine This system helps control oxides of nitrogen by recirculating a part of the exhaust gas into theengine, there by reducing cylinder combustiontemperature. The EGR system helps reduce Nox (Oxides of Nitrogen) emission gasses.
Catalytic ConverterH020A01HP

CONSUMER INFORMATION
8-2 6.0Jx15 7.0Jx16
TYRE
SIZE
RIM
SIZE PRESSURE, kPa (PSI)
P235/75R15P255/65R16 REAR
200 (29)200 (29) FRONT
200 (29)200 (29)
NORMAL LOAD
MAXIMUM LOAD
REAR
220(32)220(32)
FRONT200 (29)200 (29)
SI060A1-E
TYRE BALANCING
Incorrect tyre balance will cause steering vibra-
tion and uneven tyre wear. The vehicle tyres are balanced during production but may needfurther balancing throughout the life of the tyres.
It is recommended that the tyres be balanced
on the car for best results and that the tyres arebalanced whenever they have been removedfrom the wheel for repair.
HPI030A1-E SNOW TYRES If you equip your car with snow tyres, they should be the same size and have the sameload capacity as the original tyres. Do not drivefaster than 70 mph (112 Km/h) when your car isequipped with snow tyres. I050A02Y-EAT TYRE CHAINS Tyre chains, if necessary, should be installed on the front wheels. Be sure that the chains arethe proper size and that they are installed inaccordance with the manufacturer's instruc-tions. To minimize tyre and chain wear, do not con- tinue to use tyre chains when they are no longerneeded. WARNING: When driving on roads covered with snow or ice, drive at less than 20 mph (30 km/h).
HA1409Spare tyre SI060B1-E
TYRE REPLACEMENT
Wear indicator
0.06 in.(1.6 mm)
HGK248
Tyres must be replaced when the wear indica-
tors appear as a solid bar across the tyre tread. At this point, the remaining tread depth will beapproximately 0.06 in.(1.6 mm). In addition tothis, the tyre must be replaced if any portion ofthe tread has become bald or if there are anylumps, bulges or deep cuts in the sidewalls ortread.
Replacement tyres must be of the recommended
size and rating and should be of the samemanufacture and tread pattern on each axle.
I060A01HP-EAT
TYRE ROTATION
Tyre wear will vary for each wheel. In order to
increase the life of each tyre and keep wearuniform, tyre rotation should be performed ev-ery 3,000 miles as shown in figure. NOTE: Do not mix bias-ply and radial-ply under any
circumstances. This may cause dangerous handling characteristics.

INDEX
10-4 R Rear Seat
Adjustable headrests ..................................................................... 1-14
Folding rear seatback and seat cushion ....................................... 1-15
Rear Seat Warning........................................................................... 1-16
Rheostat Switch ................................................................................ 1-46
Roof Bars .......................................................................................... 1-55
Running in Your New Hyundai ........................................................... 1-2
S Seat Belts 2-Point Sta tic Type ....................................................................... 1-18
3-Point system ................................................................... 1-17 ~ 1-18
Adjusting your seat belt ................................................................ 1-18
Care of seat belts ......................................................................... 1-17
Pre-tensioner Seat Belt ................................................................. 1-24
Precautions ................................................................................... 1-16
Seat Warmer ..................................................................................... 1-14
Sound
Brake Pad Wear Warning Sound .................................................1-38
Spark Plugs ........................................................................................ 6-8
Speedometer ..................................................................................... 1-39
Starting Procedure .............................................................................. 2-4Steering Wheel Free play ....................................................................................... 6-15
Tilt lever ........................................................................................ 1-59Stereo Sound System ............................................................ 1-75 ~ 1-76 Sun-visor
........................................................................................... 1-57
Sunroof ................................................................................... 1-48 ~ 1-49
TTachometer ....................................................................................... 1-40
Theft-Alarm system .................................................................... 1-7 ~ 1-8
Tyres
Balancing ......................................................................................... 8-2
Chains ............................................................................................. 8-2
Changing a flat ty re ................................................................ 3-4 ~ 3-9
In the event of a puncture ..... .......................................................... 3-4
Information ....................................................................................... 8-1
Pressures ........................................................................................ 8-1Replacement ................................................................................... 8-3
Rotation ........................................................................................... 8-2
Snow tyres ...................................................................................... 8-2
Spare tyre ....................................................................................... 3-3 Spare tyre and tools ....................................................................... 8-3
Towing A trailer (or vehicle) ........................................................... 2-17 ~ 2-19
Emergency .................................................................................... 3-10
If your car must be towed ..... .......................................................... 3-9
Important trailer weight information ............................................... 2-18