steering Hyundai Terracan 2003 Repair Manual

OWNER MAINTENANCE 6-3
G030A01FC-EAT
ENGINE OIL
The correct engine oil level is of paramount
importance. An excessively high or low oil level may result in irreparable damage being sus-tained by the engine. The engine oil level mustbe checked on a daily basis, whenever thevehicle is refuelled or before starting a long trip,whichever occurs sooner.
In addition, it is imperative that only an ap-
proved grade and specification of oil is used toavoid the possibility of serious engine damageand premature wear. The use of "budget price"oil is a false economy that must be avoided ifthe maximum reliability and useful life is to beobtained from the vehicle.
SG020B1-E
DAILY OPERATING CHECKS The following items should be checked on a
daily basis or whenever the vehicle is refuelled,whichever occurs sooner.
o Engine oil level.
o Coolant level.
o Power steering fluid level.
o Brake fluid level.
o Windscreen washer fluid level.
o Battery condition.
o Tyre condition and pressures.
o Operation and cleanliness of all lighting equipment.
o Windscreen wiper and washer operation.
o Horn operation.
o Warning light operation.
o Adjustment and cleanliness of mirrors.
o Seat and seat belt adjustment and opera- tion.
o Fluid leakage.
The vehicle must not be driven if the daily
operating checks indicate that any item of equip-ment related to the safety or roadworthiness ofthe vehicle is not functioning correctly. G030B01HP-EAT
Recommended Oil
1. Petrol Engine
A multi grade oil having a specification which
meets A.P.I. specification of SG, SG/CD, SH or SH/CD is recommended. The oil viscosity shouldbe selected according to the operating environ-ment of the engine by means of the table shownabove. The engine oil recommendations arecomplete in themselves and the use of addi-tives is neither required nor recommended. Theuse of engine oil additives may result in invali-dation of the vehicle warranty.
NOTE:The use of a 5W-20 multi grade oil is not
recommended for sustained high speed use.
G030B01HP

OWNER MAINTENANCE 6-15
YG170A1-E CLUTCH PEDAL
SSA6160A
0.24~0.51 in. (6~13 mm)
The clutch pedal freeplay must lie within the limits shown. Incorrect freeplay can result inpremature wear of the clutch linings and re-lease bearing. Excessive free-play can result ingear selection difficulties. If the freeplay is incorrect, the clutch cable should be adjusted by a Hyundai dealer. G170A01A-GAT
CHECKING BRAKE PEDAL FREEPLAY
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 inresistance. 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 orrepaired if necessary.
SSA6170A
0.12 ~ 0.31 in. (3 ~ 8 mm)
To check the steering wheel free-play, stop the car with the wheels pointed straight ahead andgently move the steering wheel back and forth.Use very light finger pressure and be sensitiveto changes in resistance that mark the limits ofthe free-play. If the free-play is greater than specified, have it inspected by your Hyundai dealer and adjustedor repaired if necessary.
G150A01HP
Maximum
1.18 in (30 mm)
YG180A1-E STEERING WHEEL

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 6-19
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.

CONSUMER INFORMATION 8-1
YI000A1-E
8. CONSUMERINFORMATION
8
DI070A1-E VEHICLE IDENTIFICATION NUMBER (VIN)
I010A01HP-E
I030A01HP.DAG
I010B03HP
I010B01HP
Petrol Engine
The vehicle identification number (VIN) is unique to each individual vehicle and is the number(sometimes referred to as chassis number)used upon the vehicle registration document toidentify the vehicle. The VIN will be found stamped upon a plate attached to the engine bulkhead. I010B01A-AAT Engine Number The engine number is stamped on the engine block as shown in the drawing.
ZI010C1-E TYRE INFORMATION The tyres supplied on your new Hyundai are chosen to provide the best performance fornormal driving. YI010B1-E TYRE PRESSURES In modern high-speed motoring, correct tyre pressures are vitally important. Incorrect pressures can reduce adhesion, af- fect the steering, and cause excessive tyrewear. Check the pressures before you start atrip, when tyres are cold. If the pressures aremeasured when the tyres are warm, a higherreading will be obtained. The correct tyre pres-sures are indicated on the label affixed in thedriver's door edge and below.
Diesel Engine

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.

VEHICLE SPECIFICATIONS 9-1
J050A02HP-GAT BRAKE
Dual hydraulic with brake booster Ventilated discDisc type Cable operated on rear wheel
TypeFront brake type Rear brake type
Parking brake
J030A01HP-EAT TYRE
16.5 lmp.gal (75 litre)
9. VEHICLE SPECIFICATIONS
Overall length Overall widthOverall height Wheel base Wheel tread
Front Rear
Type Wheel free playOil pump typeBall and nut, torsion bar type (Integral type) 0 ~ 1.18 in. (0 ~ 30 mm)Vane type
J010A01HP-EAT MEASUREMENT J020A01HP-EAT POWER STEERING J060A01HP-EAT FUEL SYSTEM
185.4 (4710)
73.2 (1860) 70.6 (1795)
108.2 (2750)
60.2 (1530)60.2 (1530) Standard Option Spare
ITEM Battery Alternator
J040A02HP-EAT ELECTRICAL
PETROL
MF 68 AH
120 A (13.5 V) DIESEL
MF 100 AH
110 A (12 V)
Fuel tank capacity
9
in. (mm) 235/75 R15 225/65 R16
Full Size

VEHICLE SPECIFICATIONS
9-4 Oil & Coolant
HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4) MOBILE DEXRON- II
ATF DEXRON-IIIHYPOID GEAR OIL API GL-5 or HIGHER,SAE 80W[BELOW -22°F (-30°C)]/90W[ABOVE -22°F (-30°C)]MOBIL INFILREX 33HYPOID GEAR OIL API GL-5 or HIGHER,SAE 80W[BELOW -22°F (-30°C)]/90W[ABOVE-22°F (-30°C)]Ethylene glycol base for aluminiumPSF-3 or ATF Dexron 2DOT 3 or DOT 4 Equivalent
Q'ty (lmp.qts)(litre)
2.82 (3.2) Petrol : 9.24(10.5), Diesel : 10.38 (11.8)1.25(1.42)Part-time 4WD : 1.58(1.8)Full-time 4WD : 1.14(1.3) NO.7 : 2.9(2.6) NO.7.5 : 2.46(2.8) Petrol : 9.68 (11), Diesel : 5.28(9) 1.14 (1.3)As required
Item
Transmission Manual
Fluid AutoTransfer case oilFront axle gear oil Rear axle gear oil Coolant Power steering gearBrakes and clutch fluid
J080A06HP-EAT LUBRICATION CHART
With LSD Without LSD

INDEX10-3
M Maintenance Requirements
Explanation of scheduled maintenance items ........................ 5-6 ~ 5-8
Maintenance and servicing requirements ....................................... 5-1
Maintenance under severe usage conditions ................................. 5-5
Regular servicing ................................................................... 5-2 ~ 5-4
Mirrors Day/night inside rearview .............................................................. 1-53
Outside rearview ........................................................................... 1-51
Multi Function Switch
Headlight flash .............................................................................. 1-42
High and low beam ....................................................................... 1-42
Lane change signal ....................................................................... 1-41
Lighting switch ............................................................................... 1-42
Sidelight auto cut .......................................................................... 1-42
Turn signal operation .................................................................... 1-41
OOdometer .......................................................................................... 1-40
P Parking Brake ................................................................................... 1-53
Part-time 4WD Operation ......................................................... 2-9 ~ 2-11
Power Driver's Seat .......................................................................... 1-12
Power Outlet ..................................................................................... 1-46
Power Steering Fluid Level ............. ..................................................6-19
I Ignition Switch
..................................................................................... 2-2
Immobiliser System .................................................................... 1-2 ~ 1-4
Key ........................................................................................... 1-2, 1-4
Indicator and Warning Lights ................................................. 1-35 ~ 1-38
Instrument Cluster and Indicator ............................................ 1-31 ~ 1-34
Instruments and Controls ................ ..................................................1-30
Intermittent Wipe Facilit .................................................................... 1-44
J Jump Starting ...................................................................................... 3-2
K
Key ............................................................................................... 1-2, 1-4 If you lose your keys .................................................................... 3-11
Positions .......................................................................................... 2-2
LLimited-Slip Differential ..................................................................... 2-14
Luggage Compartment Cargo Security Screen .................................................................. 1-55
Light ............................................................................................... 1-54
Net ................................................................................................. 1-54

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