Interval Hyundai Terracan 2004 Owner's Guide

VEHICLE MAINTENANCE REQUIREMENTS
5- 2 YF010A2-E
REGULAR SERVICING
In order to ensure continued reliability, safety and longevity, regular
maintenance performed at the intervals specified is essential. The maintenance intervals specified are based both on time elapsed andmileage covered since the previous maintenance service was per-formed. However, under severe operating conditions, certain scheduledoperations should be performed at shorter intervals. Regular maintenance should be entrusted to a Hyundai dealer who is
best able to provide the expertise required to ensure optimum opera-tional performance.
In addition the use of Hyundai replacement parts and service consumables
will ensure that the original build quality, operational performance andsafety are maintained.
F030B01HP-EAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
ENGINE CONTROL SYSTEM MAINTENANCE (PETROL) ENGINE OIL & FILTER (API SG, SG/CD, SH OR SH/CD) DRIVE BELT (ALT, DAMPER, TENSIONER, IDLER) FUEL FILTER (MPI TYPE) FLUID LEAKS TIMING BELT VENTILATION HOSES AIR CLEANER FILTER SPARK PLUGS (PLATINUM COATED)
NO. DESCRIPTION60 72
5060
4048
3036
2024
1012
MILES X 1000 MONTHS
R
I I
l
R R
R
I
R
I
R
l
R
I
R
R
I I I I
R
l
I
R
R
I I1 2 3 4 5 6 7 8

VEHICLE MAINTENANCE REQUIREMENTS 5-5
F040A05HP-EAT
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals. R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
SEVERE DRIVING CONDITIONS
A - Repeated short distance driving
B - Extensive idling
C - Driving in dusty, rough roads
D - Driving in areas using salt or other corrosive materials or in very cold weather
E - Driving in sandy areas ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS (FOR PETROL ENGINE) TIMING BELT BRAKE PADS, CALIPERS AND ROTORS REAR BRAKE DRUMS/LININGS/PADS, PARKING BRAKE STEERING GEAR BOX, LINKAGE & BOOTS/ LOWER ARM BALL JOINT DRIVESHAFTS & BOOTS MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION FLUID AND FILTERTRANSFER CASE OIL *1AXLE GEAR OIL *1
EVERY 4,500 MILES OR 6 MONTHS MORE FREQUENTLY MORE FREQUENTLY EVERY 37,000 MILES OR 48 MONTHS MORE FREQUENTLY MORE FREQUENTLY MORE FREQUENTLYEVERY 9,000 MILES OR 12 MONTHS EVERY 60,000 MILESEVERY 27,000 MILESEVERY 60,000 MILES MORE FREQUENTLY
MAINTENANCE
OPERATIONMAINTENANCE ITEM
R
R R R II II
R R R I A, B, C, F, H C, EG, H, I, J D, E, F, G C, D, G, HC, D, G, H C, D, E, FC, D, E, F A, C, D, E, F, G, H, I, JA, C, E, F, G, H, I C, E, G, H, I C, E, G, H, I
MAINTENANCE INTERVALS
DRIVING
CONDITION
F - More than 50% driving in heavy city traffic during hot weather above 32°F(90°C)
G - Driving in mountainous areas
H - Towing a trailer
I - Driving for patrol car,taxi,commercial car or vehicle towing
J - Driving over 100 MPH
*1: Transfer Case Oil and Axle Gear Oil should be checked (and replaced if necessary) anytime they have been submerged in water over 15.7 in. (40cm) deep.

VEHICLE MAINTENANCE REQUIREMENTS
5- 6
F060B01A-AAT
o Drive belts Inspect all drive belts for evidence of cuts, cracks, excessive wear or oil and replace ifnecessary. Drive belts should be checkedperiodically for proper tension and adjusted asnecessary. F060C01A-AAT
o Fuel filter A clogged filter can limit the speed at which the vehicle may be driven, damage the emissionsystem and cause hard starting. If an exces-sive amount of foreign matter accumulates inthe fuel tank, the filter may require replace-ment more frequently. After installing a new filter, run the engine for several minutes, and check for leaks at theconnections. Fuel filters should be installed bytrained technicians.
F060M01A-AAT o Engine oil and filterThe engine oil and filter should be changed at the intervals specified in the maintenanceschedule. If the car is being driven in severeconditions, more frequent oil and filter changesare required.
F060D01TB-AAT
o Fuel lines, fuel hoses and connec-
tions
Check the fuel lines, fuel hoses and connec-tions for leakage and damage. Have a trainedtechnician replace any damaged or leakingparts immediately.
WARNING (Diesel only): Never work on injection system with en-gine running or within 30 seconds aftershutting off engine. High pressure pump,rail, injectors and high pressure pipes aresubject to high pressure even after theengine stopped. The fuel jet produced byfuel leaks may cause serious injury, if ittouch the body. People using pacemak-ers should not move than 30cm closer tothe ECU or wiring harness within theengine room while engine is running,since the high currents in the CommonRail system produce considerable mag-netic fields. F060E01A-AAT
o Timing beltInspect all parts related to the timing belt for damage and deformation. Replace any dam-aged parts immediately. F060G01A-EAT
o Vapour hose and fuel filler cap The vapour hose and fuel filler cap should be inspected at those intervals specified in themaintenance schedule. Make sure that a newvapour hose or fuel filler cap is correctlyreplaced.
F060F01A-AAT
o Vacuum, crankcase
ventilation hoses
Inspect the surface of hoses for evidence of
heat and/or mechanical damage. Hard andbrittle rubber, cracking, tears, cuts, abrasions,and excessive swelling indicate deterioration.Particular attention should be paid to examinethose hose surfaces nearest to high heatsources, such as the exhaust manifold.
Inspect the hose routing to assure that the
hoses do not come in contact with any heatsource, sharp edges or moving componentwhich might cause heat damage or mechani-cal wear. Inspect all hose connections, suchas clamps and couplings, to make sure theyare secure, and that no leaks are present.Hoses should be replaced immediately if thereis any evidence of deterioration or damage.
F060A01A-AAT
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS

VEHICLE MAINTENANCE REQUIREMENTS 5-7
F070E02HP-GAT
o Automatic transmission fluid and
filter
The fluid level should be in the "HOT" range of the dipstick, after engine and transmissionand filter are at normal operating temperature.Check the Automatic and filter Transmissionand filter Fluid level with the engine runningand the transmission and filter in neutral, withthe parking brake properly applied. Use MOBILDEXRON- when adding or changing fluid.
F070F01A-AAT
o Brake hoses and lines Visually check for proper installation, chafing, cracks, deterioration and any leakage. Re-place any deteriorated or damaged parts im-mediately. F070G02A-AAT o Brake fluidCheck brake fluid level in the brake fluid reservoir. The level should be between "MIN"and "MAX" marks on the side of the reservoir.Use only hydraulic brake fluid conforming toDOT 3 or DOT 4. F070H01HP-AAT
o Rear brake drums, linings and pads
parking brake
Check the rear brake drums, linings and pads
for scoring, burning, leaking fluid, brokenparts, and excessive wear. Inspect the park-ing brake system including the parking brakelever and cables. For detailed service proce-dures, refer to the Shop Manual.
F070J01A-AAT
o Brake pads, calipers and rotors
Check the pads for excessive wear, discs for
run out and wear, and calipers for fluid leak-age. F070K01A-AAT
o Exhaust pipe and muffler Visually inspect the exhaust pipes, muffler and hangers for cracks, deterioration, or dam-age. Start the engine and listen carefully forany exhaust gas leakage. Tighten connec-tions or replace parts as necessary. F070L01A-AAT
o Suspension mounting bolts Check the suspension connections for loose- ness or damage. Retighten to the specifiedtorque.
F060H01A-AAT
o Air cleaner filter
A Genuine Hyundai air cleaner filter is recom-mended when filter is replaced. F060J01A-AAT
o Spark plugs (For Petrol Engine) Make sure to install new spark plugs of the
correct heat range.
F070C01A-AAT
o Coolant The coolant should be changed at the intervals specified in the maintenance sched-ule. F070D01HP-AAT
o Manual transmission oil Inspect the manual transmission oil according to the maintenance schedule.
NOTE: If the oil level is low, check for possibleleaks before adding oil. Do not overfill.

OWNER MAINTENANCE 6-5
If the indicated oil level is at or below the lower
mark of the dipstick, oil should be added until the level is at or below the upper mark.
To add oil to the engine, remove the filler cap by
rotating in an counterclockwise direction andpour engine oil into the engine. Before checkingthe level again, allow several minutes for the oilto drain into the sump. Replace the oil filler caprotating it in a clockwise direction until tight.
The quantity of oil required to raise the level
from the minimum to maximum level is approx-imately 1 litre (Petrol Engine)/1.4 litres (DieselEngine). G350A01A-EAT
ENGINE OIL CONSUMPTION
Function of engine oil Engine oil has the primary function of lubricat-
ing and cooling the inside of the engine.
Engine oil consumption It is normal that an engine should consume
some engine oil whilst normal driving.
The causes of oil consumption in a normal
engine are as follows;
o Engine oil is used to lubricate pistons, piston rings and cylinders. A thin film of oil is left on the cylinder wall when a piston moves downwards in thecylinder.High negative pressure generated duringengine operation sucks some of this oil intothe combustion chamber. This oil with some oil of the cylinder wall is burned by the high temperature combustiongases during the combustion process.
o The engine oil consumption is strongly ef- fected by the viscosity and quality of oil,engine rpm and driving condition etc. More engine oil may be consumed under severe driving conditions such as highspeeds, frequent acceleration and decelera-tion, compared to normal driving.
G030D03HP-E G040A04A-EAT
ENGINE OIL AND FILTER REPLACEMENT
G040A03HP
Oil filler cap
Oil filter Drain plug
G040A01HP
Petrol Engine
Oil filter
Drain plug Oil filler cap
The engine oil and filter must be changed at the
time or mileage interval specified in the mainte- nance schedule. If the vehicle is operated un-der severe or adverse conditions, the oil andfilter must be replaced more frequently. Diesel Engine
Diesel Engine

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 6-9
Type
RC10PYPB4 (CHAMPION) PFR5N-11 (NGK)
Remark
Unleaded G070A03Y-AAT CHANGING THE AIR CLEANER FIL- TER The replacement of air cleaner filter is per- formed in the following manner.
1. Unsnap the clips around the cover.
2. When this is done, the cover can be lifted
off, the old filter removed and the new filter put in its place.
Genuine Hyundai replacement parts are rec-ommended. CAUTION:
o Operating your vehicle without a proper air cleaner filter in place can result in excessive engine wear.
o When removing the air cleaner filter, be careful that dust or dirt does not enterthe air intake. These may result in dam-age to the air cleaner filter.
G070A01HPG080A01HP
ZG080A2-E
WINDSCREEN WIPER BLADES
G060B03L-EAT
Replacing the Spark Plugs
The spark plugs should be changed at the
intervals specified in the vehicle maintenance schedule in Section 5 or whenever engine per-formance indicates they should be changed.Symptoms that suggest poor spark plug perfor-mance include engine misfiring under load, lossof fuel economy, poor acceleration, etc. Whenspark plugs are replaced, always use sparkplugs recommended by Hyundai. The use ofother spark plugs can result in loss of perfor-mance, radio interference or engine damage.
NOTE:
o When replacing the spark plug, Genuine Hyundai Replacement Parts are recom-mended.
Recommended Spark Plugs: The wiper blades should be carefully inspected
from time to time and cleaned to remove accu-mulations of road film or other debris.
To clean the wiper blades and arms, use a
clean sponge or cloth with a mild soap ordetergent and water.
If the wipers continue to streak or smear the
glass, replace them with genuine Hyundai re-placement parts or their equivalent.
NOTE:
o Do not operate the wipers on dry glass. This can result in more rapid wear of thewiper blades and may scratch the glass.
o Keep the blade rubber out of contact with petroleum products such as engineoil, petrol, etc.
o It is recommended that spark plugs be
changed by an authorized Hyundai dealer.
WARNING: It is recommended that the engine be cool
or cold when changing the spark plugs. If the engine is hot, you could burn yourselfon the insulated connector, the spark plugor the engine itself.

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 6-11
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 6-13
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