check engine Hyundai Terracan 2004 Owner's Guide

WHAT TO DO IN AN EMERGENCY
3-2 tinue to apply water to the affected area with a sponge or cloth.
o The gas produced by the battery during the
jump-start operation is highly explosive. Do not smoke or allow a spark or an open flame in the vicinity.
o The battery being used to provide the jump
start must be 12-volt. If you cannot determine that it is a 12-volt battery, do not attempt to use it for the jump start.
o To jump start a car with a discharged battery,
follow this procedure exactly:
1. If the booster battery is installed in another vehicle, be sure the two vehicles are nottouching.
2. Turn off all unnecessary lights and acces-
sories in both vehicles.
3. Attach the clamps of the jumper cable in the
exact location shown in the illustration. First, attach one clamp of the jumper cable to the positive (+) post or cable of the discharged battery. Then attach the other end of the same cable to the positive (+) post or cable of the booster battery. Next, using the other cable, attach one clamp to the negative (-) post or cable of the booster battery. Then attach the other end of that cable to a solid metal part of the engine away from the battery. Do not connect the cable to any moving part. 4. Start the engine in the car with the booster
battery and let it run for a few minutes. Thiswill help to assure that the booster battery is fully charged. During the jumping operation, run the engine in this vehicle at about 2000 rpm.
5. Start the engine in the car with the discharged
battery using the normal starting procedure. After the engine starts, leave the jumper cables connected and let the engine run at fast idle or about 2000 rpm for several min- utes.
6. Carefully remove the jumper cables in the
reverse order of attachment.
If you do not know why your battery became discharged (because the lights were left on, etc.), have the charging system checked by your Hyundai dealer. D030A02HP-AAT IF THE ENGINE OVERHEATS If your temperature gauge indicates overheating, you experience a loss of power, or hear loud pinging or knocking, the engine is probably too hot. If this happens to you, you should:
1. Pull off the road and stop as soon as it is safe
to do so.
2. Place the gear selector lever in "P" (auto- matic), or neutral (manual transmission) and set the parking brake. If the air conditioning is on, turn it off.
3. If engine coolant is running out under the car or steam is coming out from under the hood, stop the engine. Do not open the hood until the engine coolant has stopped running or the steaming has stopped. If there is no visible loss of coolant and no steam, leave the engine running and check to be sure the engine cooling fan is operating. If the fan is not running, turn the engine off.
4. Check to see if the water pump drive belt is
missing. If it is not missing, check to see that it is tight. If the drive belt seems to be satis- factory, check for engine coolant leaking from the radiator, hoses or under the car. (If the air conditioning had been in use, it is normal for cold water to be draining from it when you stop).

WHAT TO DO IN AN EMERGENCY 3-3
WARNING: While the engine is running, keep hands and clothing away from moving parts such as the fan and drive belts to prevent injury. 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 to high pressure even after the engine stopped. The fuel jet produced by fuel leaks may cause serious injury, if it touch the body. People using pacemakers should not move than 30cm closer to the ECU or wiring harness within the engine room while engine is running, since the high currents in the Common Rail system produce considerable magnetic fields.
5. If the water pump drive belt is broken or
coolant is leaking out, stop the engine im- mediately and call the nearest Hyundai deal- er for assistance.
WARNING: Do not remove the radiator cap when the engine is hot. This can allow coolant to be blown out of the opening and cause serious burns. D040A01HP-GAT SPARE TIREThe following instructions for the FULL SIZE spare tire should be observed: Check inflation pressure as soon as possible after installing the spare tire, and adjust to the specified pressure. The tire pressure should be periodically checked and maintained at the spec- ified pressure while the tire is stored.
Inflation Pressure
Tire Size
Full Size 200 kPa (29 psi)
Spare Tire Pressure
D040B03HP-GAT Handling the Spare Tire
1. Obtain the spare wheel rod (Jack handle)
after folding up the seat cushion of the second seat . To fold up the seat cushion, refer to the page 1-15.
The second seat
6. If you cannot find the cause of the overheat-
ing, wait until the engine temperature has returned to normal. Then, if coolant has been lost, carefully add coolant to the reservoir (Page 6-8) to bring the fluid level in the reser- voir up to the halfway mark.
7. Proceed with caution, keeping alert for fur-
ther signs of overheating. If overheating hap- pens again, call a Hyundai dealer for assis- tance.
CAUTION: Serious loss of coolant indicates there is a leak in the cooling system and this should be checked as soon as possible by a Hyundai dealer.
D040B01HP
D060B01HPB090B02HP

VEHICLE MAINTENANCE REQUIREMENTS 5-1
F010C01HP-GAT
Specified Scheduled Procedures
These are the procedures such as inspections,
adjustments and replacements that are listed in the maintenance charts starting on page 5-2.These procedures must be performed at theintervals shown in the maintenance schedule toassure that your warranty remains in effect.Although it is strongly recommended that theybe performed by the factory-trained or distribu-tor-trained technicians at your Hyundai dealer,these procedures may be performed at anyqualified service facility.
It is suggested that genuine Hyundai service
parts be used for any required repairs or re-placements. Other parts of equivalent qualitysuch as engine oil, engine coolant, manual orauto transmission oil, brake fluid and so onwhich are not supplied by Hyundai Motor Com-pany or its distributor may be used withoutaffecting your warranty coverage but you shouldalways be sure these are equivalent to thequality of the original Hyundai parts. Your Ser-vice Passport provides further information aboutyour warranty coverage.
5. VEHICLE
MAINTENANCE REQUIREMENTS F010E01A-AAT
Do-It-Yourself Maintenance If you are mechanically inclined, own a few tools that are required and want to take the time to doso, you can inspect and service a number ofitems. For more information about doing it your-self, see Section 6.
F010D01A-AAT
General Checks These are the regular checks you should per-
form when you drive your Hyundai or you fill thefuel tank. A list of these items will be found onpage 6-4.
F010A01A-GAT
MAINTENANCE INTERVALS Service Requirements
To assure that you receive the greatest number
of kilometers of satisfying operation from your Hyundai, certain maintenance procedures mustbe performed. Although careful design and en-gineering have reduced these to a minimum,those that are required are of the utmost impor-tance.
It is your responsibility to have these mainte-
nance procedures performed to comply with theterms of the warranties covering your newHyundai. The Service Passport supplied withyour new vehicle provides further informationabout these warranties.
F010B01A-AAT
Maintenance Requirements The maintenance required for your Hyundai can be divided into three main areas: o Specified scheduled procedures o General checkso Do-it-yourself maintenance F010F01A-AAT
A Few Tips
o Whenever you have your Hyundai serviced, keep copies of the service records in your glove box. This will help ensure that you candocument that the required procedures havebeen performed to keep your warranties ineffect. This is especially important whenservice is not performed by an authorizedHyundai dealer.
o If you choose to do your own maintenance and repairs, you may find it helpful to havean official Hyundai Shop Manual. A copy ofthis publication may be purchased at yourHyundai dealer's parts department.
F020A01Y-GAT
SCHEDULED MAINTENANCE RE- QUIREMENTS
Inspection should be performed any time a
malfunction is experienced or suspected. Re- ceipts for all emission control system servicesshould be retained to demonstrate compliancewith conditions of the emissions system war-ranty.
For severe usage maintenance requirements,
see page 5-6 of this section.
5

VEHICLE MAINTENANCE REQUIREMENTS 5-7
F060A01A-AAT
EXPLANATION OF SCHEDULED MAIN- TENANCE ITEMS
F060M01A-AAT
o Engine Oil and Filter The engine oil and filter should be changed at
the intervals specified in the maintenance sched- ule. If the car is being driven in severe condi-tions, more frequent oil and filter changes arerequired.
F060B01A-AAT
o Drive Belts Inspect all drive belts for evidence of cuts,
cracks, excessive wear or oil saturation andreplace if necessary. Drive belts should bechecked periodically for proper tension andadjusted as necessary.
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 replacementmore 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. F060D01TB-GAT
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 leaking partsimmediately. 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 subjectedto high pressure even after the engine hasbeen switched off. The fuel jet produced byfuel leaks may cause serious injury, if itcontacts with the body. People using pace-makers should not move closer than 30cmto the ECU or wiring harness within theengine room with the engine running, sincethe high currents in the Common Rail sys-tem produce considerable magnetic fields.
F060E01A-AAT
o Timing Belt Inspect all parts related to the timing belt for
damage and deformation. Replace any dam-aged parts immediately. F060G01A-AAT
o Vapor Hose and Fuel Filler Cap
The vapor hose and fuel filler cap should be
inspected at those intervals specified in themaintenance schedule. Make sure that a newvapor hose or fuel filler cap is correctly re-placed.
F060F01A-AAT
o Vacuum, Crankcase
Ventilation Hoses
Inspect the surface of hoses for evidence of
heat and/or mechanical damage. Hard and brit-tle rubber, cracking, tears, cuts, abrasions, andexcessive swelling indicate deterioration. Par-ticular attention should be paid to examinethose hose surfaces nearest to high heat sourc-es, 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 mechanicalwear. Inspect all hose connections, such asclamps and couplings, to make sure they aresecure, and that no leaks are present. Hosesshould be replaced immediately if there is anyevidence of deterioration or damage.

VEHICLE MAINTENANCE REQUIREMENTS
5- 8 F070E02HP-GAT
o Automatic Transmission Fluid and
Filter
The fluid level should be in the "HOT" range of the dipstick, after the engine and transmissionare at normal operating temperature. Check theautomatic transmission fluid level with the en-gine running and the transmission in neutral,with the parking brake properly applied. UseMOBIL DEXRON- II when adding or changing
fluid. F070F01A-AAT
o Brake Hoses and Lines Visually check for proper installation, chafing, cracks, deterioration and any leakage. Replaceany deteriorated or damaged parts immediate-ly. F070G02A-AAT
o Brake Fluid Check brake fluid level in the brake fluid reser- voir. The level should be between "MIN" and"MAX" marks on the side of the reservoir. Useonly hydraulic brake fluid conforming to DOT 3or DOT 4. F070H01HP-GAT
o Rear Brake Drums/ Linings/Pads,
Parking Brake
Check the rear brake drums, linings and pads for scoring, burning, leaking fluid, broken parts,and excessive wear. Inspect the parking brakesystem including the parking brake lever andcables. For detailed service procedures, referto the Shop Manual. F070J01A-AAT o Brake Pads, Calipers and RotorsCheck the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage. F070K01A-AAT o Exhaust Pipe and MufflerVisually inspect the exhaust pipes, muffler and hangers for cracks, deterioration, or damage.Start the engine and listen carefully for anyexhaust gas leakage. Tighten connections orreplace parts as necessary. F070L01A-AAT o Suspension Mounting BoltsCheck 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 the filter is replaced.
F060J01A-AAT
o Spark Plugs 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.
F070D01A-AAT
o Manual Transmission Oil Inspect the manual transmission oil according
to the maintenance schedule. NOTE:
If the oil level is low, check for possible
leaks before adding oil. Do not overfill.

VEHICLE MAINTENANCE REQUIREMENTS 5-9
F070N01A-AAT
o Power Steering Pump, Belt and
Hoses
Check the power steering pump and hoses for
leakage and damage. Replace any damaged or leaking parts immediately. Inspect the powersteering belt for evidence of cuts, cracks, ex-cessive wear, oiliness and proper tension. Re-place or adjust it if necessary.
F070P01A-AAT
o Driveshafts and Boots Check the drive shafts, boots and clamps for
cracks, deterioration, or damage. Replace anydamaged parts and, if necessary, repack thegrease.
F070Q01A-AAT
o Air Conditioning Refrigerant Check the air conditioning lines and connec-
tions for leakage and damage. Check air condi-tioning performance according to the relevantshop manual if necessary. F070M01B-AAT
o Steering Gear Box, Linkage & Boots/
Lower Arm Ball Joint, Upper Arm Ball Joint
With the vehicle stopped and engine off, check
for excessive free-play in the steering wheel.
Check the linkage for bends or damage. Check
the dust boots and ball joints for deterioration, cracks, or damage. Replace any damaged parts.

DO-IT-YOURSELF MAINTENANCE
6-4
G020A01A-AAT GENERAL CHECKS Engine Compartment The following should be checked regularly:
o Engine oil level and condition
o Transmission fluid level and condition
o Brake fluid level
o Clutch fluid level
o Engine coolant level
o Windshield washer fluid level
o Accessory drive belt condition
o Engine coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level
o Battery condition
o Air filter condition G020B01A-AAT Vehicle Exterior The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut torque
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and body corrosion
o Fluid leaks
o Door and hood lock condition
o Tire pressure and condition (including
spare tire) G020C01A-AAT Vehicle InteriorThe following should be checked each time when the vehicle is driven:
o Lights operation
o Windshield wiper operation
o Horn operation
o Defroster, heating system operation (and air
conditioning, if installed)
o Steering operation and condition
o Mirror condition and operation
o Turn signal operation
o Accelerator pedal operation
o Brake operation, including parking brake
o Manual transmission operation, including clutch operation
o Automatic transmission operation, including "Park" mechanism operation
o Seat control condition and operation
o Seat belt condition and operation
o Sunvisor operation If you notice anything that does not operate correctly or appears to be functioning incorrect- ly, inspect it carefully and seek assistance from your Hyundai dealer if service is needed. G030A01A-AAT CHECKING THE ENGINE OILEngine oil is essential to the performance and service of the engine. It is suggested that you check the oil level at least once a week in normal use and more often if you are on a trip or driving in severe conditions. G030B03HP-GAT Recommended Oil 1. Gasoline Engine
(1) Select engine oil of the proper SAE viscosity
number according to the atmospheric tem- perature. Recommended viscosity is given in the fol- lowing illustration.
G030B01HP
NOTE: SAE 5W-20 is not recommended for sus- tained high speed vehicle operation.
Gasoline Engine

DO-IT-YOURSELF MAINTENANCE 6-5
G030B02HP
(2) The engine oil quality should meet the fol-
lowing API classification. Europe : SG, SG/CD, SH OR SH/CD Except Europe : SE or ABOVE
2. Diesel Engine
(1) Select engine oil of the proper SAE viscosity number according to the atmospheric tem- perature.Recommended viscosity is given in the fol- lowing illustration.
NOTE: For diesel-powered vehicle (2.5 TCI only) SAE 5W-30 oil should be used only in areas where extremely cold temperatures of 10°C(50°F) or below are experienced. For diesel-powered vehicle (2.5 TCI only), ifthe atmospheric temperatures are 0°C (32°F) or below, SAE 30 oil must not be used. This oil should be used only in areas where the atmospheric temperatures are 0°C (32°F) or above.
(2) The engine oil quality should meet the fol-lowing API classification:
Diesel Engine (2.5 TCI) : CF-4 or ABOVE Diesel Engine (2.9 CRDi) : CF-4 or ABOVE
(3) The engine oil quality should meet the fol- lowing ACEA classification :
Diesel Engine (2.5 TCI) : B2 or B3 Diesel Engine (2.9 CRDi) : B4 or ABOVE
G030B03HP
Diesel Engine (2.5 TCI) Diesel Engine (2.9 CRDi)
G030C01HP-AAT To Check the Oil LevelBefore checking the oil, warm up the engine to the normal operating temperature and be sure your car is parked on level ground. Turn the engine off.
G030C02HP-1
NOTE: Before checking or adding the engine oil, remove the cover above the engine oil filler cap and the engine oil level dipstick with a blade screwdriver inserted in the notch (2.5 TCI only).

DO-IT-YOURSELF MAINTENANCE
6-6
G350A01A-GAT 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 while normal driving. The cause 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 the cylinder. High negative pressure generated during engine operation sucks some of the oil into the combustion chamber.This oil with some oil of the cylinder wall is
burned by the high temperature combustion gases during the combustion process.
1. Remove the oil filler cap by turning it counter-
clockwise.
2. Add oil, then check the level again. Do not overfill.
3. Replace the cap by turning it clockwise. The distance between the "F" and "L" marks is equal to about 1 liter (Gasoline Engine)/ Diesel Engine (2.5 TCI)/ 1.4 liters (Diesel Engine (2.9 CRDi)) of oil.
G030D01HP-GAT Adding Oil
G030D01HP-D
Gasoline
G030D02HP
Diesel (2.9 CRDi)
Diesel (2.5 TCI)
G030C01HP-D
G030C02HP
Diesel (2.9 CRDi)
Diesel (2.5 TCI)
Gasoline
Wait five minutes, then remove the dipstick, wipe it off, fully reinsert the dipstick and with- draw it again. Then note the highest level the oil has reached on the dipstick. It should be be- tween the upper ("F") and lower ("L") range. If the oil level is close to or below the "L" mark, add oil until it reaches the "F" mark. To add oil:

DO-IT-YOURSELF MAINTENANCE
6-8
G050B01A-DAT Recommended Engine Coolant
35% 65%
40% 60%
50% 50%
60% 40%
Ambient
temperature °C ( °F)-15 (5)
-25 (-13) -35 (-31)-45 (-49)
Antifreeze solution Water
Engine Coolant concentration
G050B01HP
G050C01A-AAT
To Check the Coolant Level
G050C01HP
Use a high quality ethylene-glycol coolant in a 50/50 mix with water. The engine coolant should be compatible with aluminum engine parts. Additional corrosion inhibitors or additives should not be used. The cooling system must be main- tained with the correct concentration and type of engine coolant to prevent freezing and corro-
Gasoline or Diesel (2.5 TCI)
G050B03HP
Diesel (2.9 CRDi) sion. Never allow the concentration of anti- freeze to exceed the 60% level or go below the 35% level, otherwise damage to the cooling system may result. For proper concentration when adding or replacing the engine coolant, refer to the following table.
8. Start the engine and check to be sure no oil
is leaking from the drain plug or oil filter.
9. Shut off the engine and recheck the oil level. NOTE: Always dispose of used engine oil in anenvironmentally acceptable manner. It is sug- gested that it be placed in a sealed container and taken to a service station for reclama- tion. Do not pour the oil on the ground or put it into the household trash. WARNING: Used motor oil may cause irritation or can- cer of the skin if left in contact with the skin for prolonged periods of time. Wash your hands thoroughly with soap and warm wa- ter as soon as possible after handling used oil. G050A01A-AAT CHECKING AND CHANGING THE EN- GINE COOLANT WARNING: Do not remove the radiator cap when the engine is hot. When the engine is hot, the engine coolant is under pressure and may erupt through the opening if the cap is removed. You could be seriously burned if you do not observe this precaution. Do not remove the radiator cap until the radiator is cool to touch.