Brake Hyundai Terracan 2004 Owners 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
6-6
To replace the oil and filter, proceed as follows:
1. Ensure that the engine is at normal operat- ing temperature and park the vehicle on level ground with the parking brake securelyapplied and the engine turned off.
2. Open the bonnet and remove the oil filler cap.
3. Prepare a suitable receptacle to collect the displaced oil and remove the drain plug fromthe sump.
CAUTION: The oil being drained from the engine will be
hot. Care should be exercised to prevent scalding.
4. When the oil has drained from the sump, replace the drain plug using a new washer ensuring that the plug is not over tightened. Tightening torque is: 3.5 ~ 4.5 kgf.m
5. Remove the oil filter by rotating counter- clockwise, using a proprietary oil filter re- moval tool if necessary. Note that the oilfilter will contain approximately 0.5 litres ofoil and this should be collected in a suitablereceptacle.
6. Install a new oil filter having smeared the sealing ring with clean oil and rotating clock-wise until the filter contacts the mountingand then a further one half turn. Do not over-tighten. Tightening torque: Petrol Engine - 1.2 ~ 1.6 kgf.mDiesel Engine - 2.3 ~ 2.5 kgf.m
7. Pour the specified quantity of the recom- mended oil into the engine and replace the filler cap. Start the engine and ensure thatno oil leaks exist. Turn off the engine andafter a couple minutes, recheck the oil level.
WARNING: Prolonged and repeated contact with used engine oils may result in serious skin disor-ders including dermatitis and cancer. Avoidcontact with skin as far as possible andalways wash thoroughly after any contact.Keep used oils out of reach of children. It isillegal to pollute drains, water courses andsoil. Use only authorized waste collectionfacilities including civic amenity sites andgarages for the disposal of used oil and oilfilters. If in doubt, contact the local authorityfor disposal instructions. SG050A1-E
ENGINE COOLANT CHECKING AND REPLACING
WARNING: Do not remove the radiator cap when the engine is hot, since the system is pressur-ized and coolant may be ejected from theradiator resulting in scalding. SG050B1-E
Coolant recommendations Only ethylene glycol based coolant with a cor- rosion inhibitor suited to aluminium alloy enginecomponents should be used in the coolingsystem. No further additives or inhibitors shouldbe used. The coolant specific gravity should bechecked as prescribed in the maintenanceschedule to ensure adequate frost and corro-sion protection. In addition, the engine coolantmust be replaced at the specified interval sincethe corrosion inhibitor properties deteriorate withtime. It is important to note that whilst an increase in the concentration of anti freeze gives an in-crease in the level of frost protection, a solutionwhich is in excess of 65% anti freeze will resultin reduced frost protection and engine over-heating. Therefore the recommended concen-tration of 50% should not be exceeded forgeneral use.The use of methanol based anti freeze com-pounds may result in engine overheating andwill invalidate the vehicle warranty.

OWNER MAINTENANCE 6-7
NOTE: It is imperative that vehicles fitted with an
air conditioning system have a coolant con- centration of the recommended strength atall times. The use of the air conditioningsystem when the cooling system is filledwith water only will result in the heatermatrix freezing and subsequently bursting.
SG050C1-E
Coolant Level
The engine coolant level may be observed
through the side of the plastic coolant reservoir(expansion tank) when the engine is cold. If thelevel is below the "LOW" mark, add coolant ofthe correct concentration until the level is be-tween the "LOW" and "FULL" marks. If the levelfalls below the "LOW" mark on a regular basisdespite being topped up, consult a Hyundaidealer. HPG050D1-E
To Change the Coolant
The coolant should be changed at those inter-
vals specified in the vehicle maintenance sched-ule in Section 5.
NOTE: Care should be taken to ensure that coolant
is not allowed to spill onto the paintwork since the finish may become damaged. Ifcoolant spillage occurs, the affected areashould be rinsed thoroughly with water.
1. Park the vehicle on level ground and ensure that the parking brake is firmly applied, and the engine allowed to cool. Do not attempt this operation whilst the engine is hot since burning or scalding mayresult.
2. Prepare a suitable receptacle to collect the displaced coolant and position this under theradiator drain tap. NOTE: Petrol Engine Only Before adding the coolant to the radiator,
unscrew the flange bolt for fitting water outlet to escape the excess pressure. And ifthe coolant overflows from the hole whileadding the coolant, screw the bolt and con-tinue to add the coolant.
3. With the heater temperature control set to the "HOT" position, remove the radiator cap and open the radiator drain tap.
G050D01HP
Petrol Engine only
G050C01HP

OWNER MAINTENANCE 6-11
G110A04HP-EAT
AUTOMATIC TRANSMISSION LUBRI- CANT Transmission lubricant should be changed at
those intervals specified in the vehicle mainte- nance schedule in Section 5.
NOTE: Basically automatic transmission fluid is red
color. As driving distance increases, the fluid color turns darkish red gradually. It isnormal condition and you should not usefluid color as a criterion for replacing thetransmission fluid.
You must replace the automatic transmis-
sion fluid in accordance with intervals speci-fied in the vehicle maintenances schedule insection 5. Recommended Lubricant
Use only MOBIL DEXRON- II. Damage caused
by a nonspecified fluid is not covered by your new vehicle limited warranty. Transmission Fluid Capacity
The fluid capacity of the automatic transmission
is 10.5 litres (Petrol)/ 11.8 litres (Diesel). CAUTION: The transmission fluid level should be
checked when the engine is at normal oper- ating temperature. This means that the en-gine, radiator, exhaust system etc., are veryhot so you should exercise great care not toburn yourself during this procedure. To Check the Transmission Fluid Level
Park the car on level ground with the parking
brake engaged. When the transmission fluid level is checked, the transmission fluid shouldbe at normal operating temperature and theengine idling.
Whilst the engine is idling, apply the brakes and
move the gear selector level from "P" to each ofits other positions — "R", "N", "D", "2", "L" —and then return to "N" or "P". With the enginestill idling:
1. Open the bonnet, being careful to keep hands and clothing clear of any moving parts.
up, add oil slowly until it reaches the properlevel. Do not overfill.
3. Replace the bolt and washer, screw it in with your fingers and then tighten securely withthe wrench.
G110D03HP.DAG
G110D01HP-E
Petrol Engine
2. Remove the transmission dipstick, wipe it clean, reinsert the dipstick as far as it will go, then remove it again. Now check the fluidlevel on the dipstick. It should be in the"HOT" range on the dipstick. G110D04HP-E
Diesel Engine

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 6-15
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.

VEHICLE SPECIFICATIONS 9-1
Option Spare
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)
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