Water Hyundai Terracan 2003 Repair Manual

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

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

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

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

OWNER MAINTENANCE
6-16 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
6-20
G260A01HP-DAT
REPLACING HEADLIGHT BULBS
Before attempting to replace a headlight bulb, be sure the switch is turned to the "OFF"position. The next paragraph shows how to reach the headlight bulbs so they may be changed. Besure to replace the burned-out bulb with one ofthe same number and wattage rating. NOTE: The passenger'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, petrol, etc.
G260A01HP
G300B01HP-GAT
REMOVAL OF WATER FROM THE FUEL FILTER (FOR DIESEL ENGINE)
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 wateras 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 isstarted.If in doubt, consult your nearest authorizedHYUNDAI dealer.
WARNING: Be sure to carefully wipe away any water
drained out in this manner, because the fuel mixed in the water might be ignited andresult in a fire.
1. Pump the hand prime pump with your hand
for one minute(about 20~30 times).
2. Turn the ignition key to the "START" posi- tion and release it 2~3 times shortly until theengine starts.
CAUTION: Do not hold the ignition key in the "START"
position for more than 15 seconds. Doing so may cause the engine and the injection pumpto damage.