warning Hyundai Terracan 2003 Repair Manual

DO-IT-YOURSELF MAINTENANCE
6-14 G140A01A-AAT
AIR CONDITIONING CARE Keeping the Condenser Clean
The air conditioning condenser (and engine
radiator) should be checked periodically for accumulation of dirt, dead insects, leaves, etc. These can interfere with maximum cooling effi- ciency. When removing such accumulations, brush or hose them away carefully to avoid bending the cooling fans. G130B02A-AAT
To Replace the Fluid Recommended brake fluid conforming to DOT
3 or DOT 4 specification should be used. The reservoir cap must be fully tightened to avoid contamination from foreign matter or moisture.
NOTE: Do not allow any other liquids to contami-
nate the brake fluid. Seal damage will result.
WARNING:Use caution when handling brake fluid. It
can damage your vision if you get it in your eyes. It will also damage your vehicle’s paint if spilled on it and not removed immediately.
G130A01A-AAT
CHECKING THE CLUTCH FLUID To Check the Clutch Fluid
G130A01HP
The clutch fluid level in the master cylinder
should be checked when performing other un- der hood services. The system should be checked for leakage at the same time. Check to make certain that the clutch fluid level is always between the "MAX" and "MIN" level markings on the fluid reservoir. Fill as required. Fluid loss indicates a leak in the clutch system which should be inspected and repaired immediately. Consult your Hyundai dealer.
G120E02A-AAT
Adding Brake Fluid
WARNING: Handle brake fluid carefully. It can damage
your vision if it gets into your eyes. Use only DOT 3 or DOT 4 specification fluid from a sealed container. Do not allow the fluid can or reservoir to remain open any longer than required. This will prevent entry of dirt and moisture which can damage the brake sys- tem and cause improper operation.
To add brake fluid, first wipe away any dirt then
unscrew the fluid reservoir cap. Slowly pour the recommended fluid into the reservoir. Do not overfill. Carefully replace the cap on the reser- voir and tighten.
G120E01HP

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 6-21
G350A01HP-GAT BLEEDING THE FUEL SYSTEM
(FOR DIESEL ENGINE (2.5 TCI))
E090A01HP
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 is replaced, or if the vehicle is not used for a long time.
G240A01A-AAT POWER STEERING HOSESIt is suggested that you check the power steer- ing hose connections for fluid leakage at regular intervals. The power steering hoses should be replaced if there is severe surface cracking, pulling, scuffing or worn spots. Deterioration of the hose could cause premature failure.
NOTE: Do not start the engine when the powersteering oil reservoir is empty.
2. Pump the hand pump until there are no more
bubbles in the fuel coming out of the air plug. When doing this, place a cloth around the air plug to prevent the escaping fuel from spew- ing about.
3. Tighten the air bleed bolt when there are no more bubbles in the fuel.
4. Continue pumping until the hand pump be- comes stiff.
5. Finally, check to be sure that there is no leakage of fuel.If in doubt, consult your nearest authorizedHYUNDAI dealer.
WARNING:
(1) Do not smoke or have any other open flame near the vehicle while bleeding the fuel system.
E090A02HP
1. Loosen the air bleed bolt at the top of the fuel
filter with a flat-bladed screwdriver or equiva- lent.
The power steering fluid level should be checked daily. To check the power steering fluid level, be surethe ignition is "OFF", then check to make cer- tain that the power steering fluid level is be- tween the "MAX" and "MIN" level markings on the fluid reservoir. NOTE: Grinding noise from the power steering pump may be heard immediately after the engine is started in extremely cold condi- tions (below - 20°C). If the noise stops dur- ing warm up, there is no abnormal function in the system. If is due to a power steering fluid characteristic in extremely cold condi- tions. Recommended Fluid Use PSF-3 type fluid.
G230A02HP
Diesel (2.9 CRDi)

DO-IT-YOURSELF MAINTENANCE
6-22
G350B01HP-GAT
BLEEDING THE FUEL SYSTEM
(FOR DIESEL ENGINE (2.9 CRDi))
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 is replaced, or if the vehicle is not used for a long time.
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 the engine starts.
NOTE:Do not hold the ignition key in the "START"position for more than 15 seconds. Doing so may cause the engine and the injection pump to damage.
G350A01HP
E090A02HP
2. Operate the hand pump slowly 6 or 7 times in order to force the water out through the drain plug.
3. Tighten the drain plug when water no longer comes out.
4. Loosen the air bleed bolt and bleed the air. (Refer to "Bleeding the fuel system")
5. 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 authorized HYUNDAI dealer.
WARNING:
(1) Do not smoke or have any other open flame near the vehicle while bleeding thefuel system.
(2) Be sure to carefully wipe away any water drained out in this manner, because thefuel mixed in the water might be ignited and result in a fire.
G300A01HP-GATREMOVAL OF WATER FROM THE FUEL FILTER (FOR DIESEL ENGINE (2.5 TCI))
E100A01HP
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) Be sure to carefully clean away any fuel
which spilled onto nearby parts coming out of the air bleed bolt, because such
accumulations of fuel might ignite andcause a fire.

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
6-26 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

7-2EMISSION CONTROL SYSTEMS
WARNING:
o Use unleaded fuel only.
o Maintain the engine in good operating condition. Extremely high catalytic con-verter temperatures can result from im- proper operation of the electrical, igni- tion or multiport electronic fuel injection.
o If your engine stalls, pings, knocks, or is hard to start, have your Hyundai dealerinspect and repair the problem as soon as possible.
o Avoid driving with a very low fuel level. Running out of gasoline may cause theengine to misfire and result in damage to the catalytic converter.
o Avoid idling the engine for periods long- er than 10 minutes.
o The vehicle should not be pushed or pulled to get started. This may cause the catalytic converter to overheat and cre- ate a fire hazard.
o Do not touch the catalytic converter or any other part of the exhaust systemwhile the catalytic converter is hot. Shut off the engine, wait for at least one hour before touching the catalytic converter or any other part of the exhaust system.
o Remember that your Hyundai dealer is your best source of assistance.
o Do not stop your Hyundai over any com- bustible material such as grass, paper,leaves or rags. These materials might contact the hot catalytic converter and a fire might result. H020C01HP-GAT EGR SYSTEM ; For a Diesel Engine (If installed) This system helps control oxides of nitrogen by recirculating a part of the exhaust gas into the engine, there by reducing cylinder combustion temperature.This system can be reduced Nox of Emission used by EGR.
H020D01S-GAT CATALYTIC CONVERTER ; For a Diesel Engine (If installed) All Hyundai vehicles are equipped with oxida- tion type catalytic converter to reduce the car- bon monoxide, hydrocarbons and particulate contained in the exhaust gas.

CONSUMER INFORMATION
8-2 I060A01HP-GAT TIRE ROTATION
I040A02S-GAT
SNOW TIRES If you equip your car with snow tires, they should be the same size and have the same load capacity as the original tires. Snow tires should be installed on all four wheels; other- wise, poor handling may result. Snow tires should carry 28 kPa (4 psi) more air pressure than the pressure recommended for the standard tires on the tire label on the driver's door edge, or up to the maximum pressure shown on the tire sidewall whichever is less. Do not drive faster than 120 km/h (75 mph)when your car is equipped with snow tires. I050A01HP-AAT
TIRE CHAINS Tire chains should be installed on the rear wheels. Be sure that the chains are installed in accordance with the manufacturer's instruc- tions. To minimize tire and chain wear, do not con-tinue to use tire chains when they are no longer needed. WARNING: When driving on roads covered with snow or ice, drive at less than 30 km/h (20 mph). Tires should be rotated every 5,000 km (3,000
miles). If you notice that tires are wearing un- evenly between rotations, have the car checked by a Hyundai dealer so the cause may be corrected.After rotating, adjust the tire pressures and be sure to check wheel nut torque. WARNING: Do not mix bias-ply and radial-ply tires un-
der any circumstances. This may cause dan- gerous handling characteristics that may
cause death, serious injury, or property dam- age.
o Lower-than-recommended tire pressures
cause uneven tread wear and poor han-dling.
o Higher-than-recommended tire pressures
increase the chance of damage from im-pacts and cause uneven tread wear.
CAUTION: Always observe the following:
o Check pressures when the tires are cold. That is, after the car has been parked for at least three hours and hasn't been driven more than 1.6 km or one mile since starting up.
o Check the pressure of your spare tire each time you check the pressure of other tires.
o Never overload your car. Be especially careful about overloading if you equipyour car with a luggage rack or car top carrier.
HA1409

CONSUMER INFORMATION 8-3
I070A01A-AAT TIRE BALANCINGA tire that is out of balance may affect handling and tire wear. The tires on your Hyundai were balanced before the car was delivered but may need balancing again during the years you own the car. Whenever a tire is dismounted for repair, it should be rebalanced before being reinstalledon the car.
I100A01HP-AAT SPARE TIRE AND TOOLS Your Hyundai is delivered with the following: Spare tire and wheel WrenchJackJack handle (Spare Wheel Rod)
I080A01A-AAT TIRE TRACTIONTire traction can be reduced if you drive on worn tires, tires that are improperly inflated or on slippery road surfaces. Tires should be re- placed when tread wear indicators appear. To reduce the possibility of losing control, slow down whenever there is rain, snow or ice on the road. I090A01Y-GAT
WHEN TO REPLACE TIRES
The original tires on your car have tread wearindicators. The tread wear indicators appear when the tread depth is 1.6 mm (0.06 in.). The tire should be replaced when these appear as asolid bar across two or more grooves of the tread. Always replace your tires with those of the recommended size. If you change wheels, the new wheel's rim width and offset must meet Hyundai specifications. WARNING:
o Driving on worn-out tires is dangerous! Worn-out tires can cause loss of braking effectiveness, steering control and trac- tion. When replacing tires, never mix ra- dial and bias-ply tires on the same car. If
you replace radial tires with bias-ply tires, they must be installed in sets of four.
D060B02HP
Wear indicator
1.6 mm (0.06 in.)
HGK248o Using tires and wheels of other than the
recommended sizes may cause unusual handling characteristics that may cause death, serious injury, or property dam- age.