Hyundai Terracan 2004 Owner's Manual

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.

VEHICLE MAINTENANCE REQUIREMENTS
5- 8
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 damagedparts. F070N01A-AAT
o Power steering pump, belt and hoses Check the power steering pump and hoses for leakage and damage. Replace any dam-aged or leaking parts immediately. Inspect thepower steering belt for evidence of cuts,cracks, excessive wear, oiliness and propertension. Replace or adjust it if necessary. F070P01HP-AAT o Driveshafts and bootsCheck 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 airconditioning performance according to therelevant shop manual if necessary.

OWNER MAINTENANCE 6-1
SG000A1-E
6. OWNER MAINTENANCE G010A01HP-EAT
PETROL ENGINE COMPARTMENT (3.5 V6)
1. Windscreen washer fluid reservoir
2. Power steering fluid reservoir
3. Clutch fluid reservoir (Not all models)
4. Brake fluid reservoir
5. Engine cover 6. Engine oil filler cap
7. Automatic transmission fluid level dipstick
(Vehicle with Automatic Transmission)
8. Battery
9. Fuse and relay box 10. Air cleaner
11. Radiator cap
12. Engine oil level dipstick
13. Coolant reservoir cap
6
G010A02HP-E
CAUTION: When inspecting or servicing the en- gine, you should handle tools andother heavy objects carefully so thatthe plastic cover of the engine is notdamaged.
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234 5 6 7
8
9
10 9
11 12 13

OWNER MAINTENANCE
6-2
G010C01HP-EAT
DIESEL ENGINE COMPARTMENT (2.9 CRDi)
1. Windscreen washer fluid reservoir
2. Brake fluid reservoir
3. Clutch fluid reservoir (Not all models)
4. Engine cover 5. Automatic transmission fluid level dipstick
(Vehicle with Automatic Transmission)
6. Battery
7. Fuse and relay box
8. Air cleaner 9. Engine oil level dipstick
10. Radiator cap
11. Engine oil filler cap
12. Fuel filter
13. Power steering fluid reservoir
14. Coolant reservoir capG010C01HP-D
CAUTION: When inspecting or servicing the en- gine, you should handle tools andother heavy objects carefully so thatthe plastic cover of the engine is notdamaged.
12
34 56
8 9 10 11 12 7 137
14

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
6-4
HPG030D1-E
ENGINE OIL REPLENISHMENT
2. Diesel Engine
The engine oil quality should meet the following classification: API: CF-4 or ABOVE ACEA: B4 or ABOVE
G030B03HP
SG030C1-E
Engine Oil Level
G030C01HP-E
G030C03HP-E
The engine oil level should be checked with the engine at normal operating temperature and thevehicle parked upon level ground. Prior to checking the level, the vehicle should be allowed to stand for several minutes after theengine has been switched off to allow the oil todrain back to the sump. Withdraw the dipstick and wipe it with a cleanrag. Replace the dipstick fully and withdrawagain when the oil level may be read from thestick. Normal oil level is indicated when the oilis present between the two marks on the stick.It is not necessary to add oil if the level is abovethe lower mark and in any case, oil must not beadded to the degree that the level exceeds theupper mark. Replace the dipstick fully afterchecking the level.
Diesel Engine
G030D01HP
Petrol Engine
Petrol Engine

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.