check engine Hyundai Terracan 2004 Service Manual

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.
CAUTION: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 BULBS Before attempting to replace a headlight bulb,
be sure the switch is turned to the "OFF" position. The next paragraph shows how to reach the
headlight bulbs so they may be changed. Besure to replace the burned-out bulb with one of the same number and wattage rating. WARNING:Be sure to carefully wipe away any water
drained 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.

CONSUMER INFORMATION 8-1
8. CONSUMER
INFORMATION
I010A01A-GAT VEHICLE IDENTIFICATION NUMBER (VIN) The vehicle identification number (VIN) is the number used in registering your car and in all legal matters pertaining to its ownership, etc. It can be found on the identification plate at-tached to the engine side of the firewall be- tween the engine and passenger compartment. I020A01A-AAT TIRE INFORMATIONThe tires supplied on your new Hyundai are chosen to provide the best performance for normal driving.
I010A01HP I030A01HP-GAT RECOMMENDED INFLATION PRES- SURES
The tire label located on the driver's side of the center pillar outer panel gives the tire pressures recommended for your vehicle.
I030A01HP
I010B01S-GAT Engine Number The engine number is stamped on the engine block as shown in the drawing.
I010B02HP
8
I010B01HP
Diesel (2.9 CRDi)
Diesel (2.5 TCI)
Gasoline
7.0Jx16
TIRE
SIZE
RIM
SIZE PRESSURE, kPa (PSI)
P255/65R16 REAR
200 (29) FRONT
200 (29)
NORMAL LOAD
MAXIMUM LOAD
REAR
220(32)
FRONT 200 (29)
These pressures were chosen to provide the most satisfactory combination of ride comfort, tire wear and stability under normal conditions. Tire pressures should be checked monthly at least. Proper tire inflation pressures should be maintained for these reasons:

INDEX
10-2 D Defrosting/Defogging
......................................................................... 1-71
Door Locking, unlocking front door with a key ........................................ 1-6
Drink Holder ...................................................................................... 1-53
Drive Belts ............................................................................... 6-15, 6-18
Driving Driving for economy ...................................................................... 2-14
Smooth cornering .......................................................................... 2-15
Winter driving ................................................................................ 2-15
E Emission Control System ................................................................... 7-1
Engine
Before starting the engine ............................................................... 2-2Compartment (3.5 V6) ..................................................................... 6-1
Compartment (2.5 TCI) ................................................................... 6-2
Compartment (2.9 CRDi) ................................................................ 6-3
Coolant ............................................................................................ 6-7
Coolant temperature gauge ........................................................... 1-43
If the engine overheats ................................................................... 3-2
Number ............................................................................................ 8-1
Oil .................................................................................................... 6-4Starting ............................................................................................ 2-3
Engine Exhaust Can Be Dangerous ................................................... 2-1
FFan Speed Con trol ................................................................... 1-66, 1-75Fog Light
Front .............................................................................................. 1-48
Rear .............................................................................................. 1-48
Front Seats
Adjustable front seats ................................................................... 1-11
Adjustable headrests ..................................................................... 1-12
Adjusting seat forward and rearward ............................................1-11
Adjusting seatback angle .............................................................. 1-11
Fuel Capacity .......................................................................................... 9-1
Gauge ............................................................................................ 1-43
Unleaded gasoline ........................................................................... 1-1
Fuel Filler Lid Remote release ............................................................................. 1-62
Full-time 4WD Operation .................... ................................... 2-10 ~ 2-13
Fuses ................................................................................................ 6-18
G General Checks .................................................................................. 6-4
Glove Box ......................................................................................... 1-56
H Hazard Warning System ................................................................... 1-51
Headlight Aiming Adjustment ............................................................ 6-24
Headlight Leveling Device System ................................................... 1-65
Heating and Ventilation
Air flow control ......................................................... 1-68 ~ 1-69, 1-77
Temperature control ...................................................................... 1-69

CONTROLS AND EQUIPMENT
1- 2 YB020A1-E BEFORE ENTERING THE VEHICLE
o Ensure that all windows, mirrors and lamps are clean.
o Check condition of all tyres.
o Ensure that no fluid leaks are evident.
o Ensure that the area around the vehicle is clear before driving off.
YB020B1-E AFTER ENTERING THE VEHICLE
o Ensure that all occupants fasten and cor- rectly adjust seat belts.
o Ensure that seat and headrestraint positions are adjusted for optimum safety, control and comfort.
o Adjust interior and exterior rear view mir- rors.
o Verify correct operation of lamps, horn and other electrical equipment.
o Ensure that warning lamps illuminate when ignition is turned on.
NOTE: Fluid levels such as engine oil, engine cool- ant, brake and windscreen washer fluidshould be checked daily or at each refuel-ling, whichever occurs sooner. B020A01FC-EAT RUNNING IN YOUR NEW HYUNDAIThe longevity and performance of the vehicle are greatly affected by the care exercised dur-ing the first 1000 miles of motoring. Because ofmodern manufacturing techniques, rigid guide-lines regarding maximum road speeds havebecome unnecessary. However, certain pre-cautions should be observed in order to obtainthe best possible performance and useful lifefrom the vehicle.
1) Do not race the engine without a load (i.e revving the engine in neutral).
2) During the first 500 miles the maximum engine speed should be restricted to 3000rpm and gradually increased thereafter.
3) Avoid prolonged constant speed operation. The internal components of the engine willbecome run-in more quickly if the operation
speed is varied during the running in period.
4) Never allow the engine to labour. Use the gearbox freely and avoid large throttle open-ings when the engine speed is below 1500rpm.
5) Avoid rapid acceleration and maximum throttle openings.
6) Avoid harsh braking during the first 100 miles of urban motoring or 1000 miles ofmotorway driving to allow the friction facingsof the brake pads and shoes to bed againstthe discs and drums properly.
7) No trailer towing should be undertaken dur- ing the running-in period. B880A01HP-EAT IMMOBILISER SYSTEM
- For Petrol Engine The immobiliser system is an anti-theft device, designed to deter automobile theft. B880B01HP-EAT Keys
B880B01HP
B880B02HP
Light Purple
ID key
ID key Master key
Master key
Type B
Black
Type A

CONTROLS AND EQUIPMENT
1- 40 B260P02Y-EAT
ABS Service Reminder Indicator Light (Not all models)
When the key is turned to the "ON" position, the
Anti-Lock Brake System SRI will come on and then go off in a few seconds. If the ABS SRIremains on, comes on while driving, or does notcome on when the key is turned to the "ON"position, this indicates that there may be aproblem with the ABS.
If this occurs, have your vehicle checked by
your Hyundai dealer as soon as possible. Thenormal braking system will still be operational,but without the assistance of the anti-lock brakesystem.
WARNING:
If both ABS SRI and Parking Brake/Brakefluid level warning lights remain "ON" orcome on whilst driving, there may be a prob-
lem with E.B.D. (Electronic Brake Force Dis-tribution). If this occurs, avoid sudden stopsand have your vehicle checked by yourHyundai dealer as soon as possible. B260F01A-AAT
High Beam Indicator Light
The high beam indicator light comes on when-ever the headlights are switched to the highbeam or flash position.
B260D01A-AAT Turn Signal Indicator Lights
The blinking green arrows on the instrument
panel show the direction indicated by the turn signals. If the arrow comes on but does notblink, blinks more rapidly than normal, or doesnot illuminate at all, a malfunction in the turnsignal system is indicated. Your dealer shouldbe consulted for repairs. B260G01A-EAT
Low Oil Pressure Warning Light
CAUTION:
If the oil pressure warning light stays onwhilst the engine is running, serious enginedamage may result. The oil pressure warninglight comes on whenever there is insufficient oil pressure. In normal operation, it should come on when the ignition switch is turnedon, then go out when the engine is started. If the oil pressure warning light stays onwhilst the engine is running, there is a seri-ous malfunction. If this happens, stop the car as soon as it is safe to do so, turn off the engine and checkthe oil level. If the oil level is low, fill engineoil to the proper level and start the engineagain. If the light stays on with the enginerunning, turn the engine off immediately. Inany instance where the oil light stays onwhen the engine is running, the engineshould be checked by an authorized Hyundaidealer before the car is driven again.B260C01A-EAT
O/D OFF Indicator (Not all models)
When the overdrive switch is turned on, the overdrive off indicator will go out. This amberindicator will be illuminated when the overdriveswitch is turned off.
B260H02A-EAT
Parking Brake/Low Brake Fluid Level Warning Light
WARNING:
If you suspect brake trouble, have your brakes checked by a Hyundai dealer as soon aspossible. Driving your car with a problem ineither the brake electrical system or brakehydraulic system is dangerous, and couldresult in a serious injury or death.
Warning Light Operation The parking brake/brake fluid level warning light should come on when the parking brake isapplied and the ignition switch is turned to "ON"or "START". After the engine is started, the lightshould go out when the parking brake is re-leased.If the parking brake is not applied, the warninglight should come on when the ignition switch isturned to "ON" or "START", then go out whenthe engine starts. If the light comes on at anyother time, you should slow the vehicle andbring it to a complete stop in a safe location offthe roadway.

CONTROLS AND EQUIPMENT1- 41
B260M01A-AATLow Fuel Level Warning Light
The low fuel level warning light comes on when
the fuel tank is approaching empty. When it comes on, you should add fuel as soon aspossible. Driving with the fuel level warning lighton or with the fuel level below "E" can cause theengine to misfire and damage the catalyticconverter.
B260K01B-EAT Hatchback Door Open Warning Light
This light remains on unless the tail gate is completely closed and latched.
B260E01HP-GAT
Seat Belt Warning Light
The seat belt warning light blinks for about 6seconds when the ignition key is turned fromthe "OFF" position to "ON" or "START".
B260L01A-GAT Door Ajar Warning Light
The door ajar warning light warns you that a
door is not completely closed.
B260A01B-GAT
Front Fog Indicator Light
Front fog indicator light comes on whenever the fog light switch is on.
B260J01S-EAT Charging System Warning Light
The charging system warning light should come on when the ignition is turned on, then go outwhen the engine is running. If the light stays onwhilst the engine is running, there is a malfunc-tion in the electrical charging system. If the lightcomes on whilst you are driving, stop, turn offthe engine and check under the bonnet. First,make certain the generator drive belt is inplace. If it is, check the tension of the belt.And then, have the system checked by yourHyundai dealer. CAUTION: If the drive belt (generator belt) is loose, broken, or missing whilst the vehicle is driv-ing, there may be a serious malfunction,engine could overheat because this belt alsodrives the water pump.
B260Q01HP-EAT Cruise Indicator Light (Not all models)
The cruise indicator light in the instrument clus-
ter is illuminated only when the vehicle cruising speed has been set using the control switch onthe steering wheel.
The indicator light does not illuminate when the
main cruise control switch is activated. Information on the use of cruise control may be
found on page 1-66.
The brake fluid level warning light indicates that
the brake fluid level in the brake master cylinderis low and hydraulic brake fluid conforming toDOT 3 or DOT 4 specifications should beadded. After adding fluid, if no other trouble isfound, the car should be immediately and care-fully driven to a Hyundai dealer for inspection.If further trouble is experienced, the vehicleshould not be driven at all but taken to a dealerby a professional towing service or some othersafe method.
Your Hyundai is equipped with dual-diagonal
braking systems. This means you still havebraking on two wheels even if one of the dualsystems should fail. With only one of the dualsystems working, more than normal pedal traveland greater pedal pressure are required to stopthe car. Also, the car will not stop in as short adistance with only half of the brake systemworking. If the brakes fail whilst you are driving,shift to a lower gear for additional engine brak-ing and stop the car as soon as it is safe to doso.

CONTROLS AND EQUIPMENT
1- 42 B260T02HP-EAT
4WD Engaged Indicator
Light (Part-time 4WD type)
When the key is turned to the "ON" position, the
4WD(Four Wheel Drive) engaged indicator light will come on and then go off in a few seconds.
The 4WD engaged indicator light will illuminate
when the transfer shift knob is set to 4H position(Part-time 4WD type). CAUTION: If the 4WD engaged indicator light ( , )blinks (Full-time 4WD type) or illuminates
with the 4WD LOW indicator light ( , )(Part-time 4WD type) whilst driving, this indi-cates that there is a malfunction in the 4WDsystem. If this occurs, have your vehiclechecked by an authorized Hyundai dealer assoon as possible.
B260U01HP-EAT A/T(Automatic Transmission)
Oil Temperature Warning Light(Not all models)
The A/T oil temperature warning light comes on when the automatic transmission oil temperaturegoes up to the temperature that may result inserious damage of automatic transmission. If the A/T oil temperature warning light comes on
whilst driving, park your vehicle in at a safe
place as soon as possible. With the selectorlever shifted into "P" position, allow the engineto idle until the warning light goes off. When thewarning light goes off, the vehicle can be driven
normally. CAUTION: If the warning light doesn't go off or blinks,this indicates that there is a malfunction inthe automatic transmission or T.C.U (Trans-mission Control Unit). If this occurs, haveyour vehicle checked by an authorizedHyundai dealer.
A/T
B260N01A-EAT
Malfunction Indicator Light
This light illuminates when there is a malfunction of an exhaust gas related component, and thesystem is not functioning properly so that theexhaust gas regulation values are not satisfied.This light will also illuminate when the ignitionkey is turned to the "ON" position, and will go out
in a few seconds. If it illuminates whilst driving,or does not illuminate when the ignition key isturned to the "ON" position, take your car to yournearest authorized Hyundai dealer and have thesystem checked.
B260R01HP-GAT 4WD LOW Indicator Light (Not all models)
When the key is turned to the "ON" position, the
4WD(Four Wheel Drive) LOW indicator light will come on and then go off in a few seconds.
The 4WD LOW indicator light comes on when
the transfer shift knob is set to low position(Part-time 4WD type : 4L position, Full-time
4WD type : LOW position).B260B01A-EAT
SRS (Airbag) Service Reminder Indicator (SRI) Light
The SRS service reminder indicator (SRI) comes on and flashes for about 6 seconds after theignition key is turned to the "ON" position orafter the engine is started, after which it will goout. This light also comes on when the SRS is not working properly. If the SRI does not come on,or continuously remains on after flashing forabout 6 seconds when you turned the ignitionkey to the "ON" position or started the engine,or if it comes on whilst driving, have the SRSinspected by an authorized Hyundai Dealer.
,
,

CONTROLS AND EQUIPMENT1- 43
B270A01A-EAT BRAKE PAD WEAR WARNING SOUND (Not all models) The front disc brake pads have wear indicators
that should make a high-pitched squealing or scraping noise when new pads are needed.The sound may come and go or be heard all thetime when the vehicle is moving. It may also beheard when the brake pedal is pushed downfirmly. Excessive rotor damage will result if theworn pads are not replaced. See your Hyundaidealer immediately. NOTE: If the engine were not started within 2 sec-
onds after the preheating is completed, turn the ignition key once more to the "LOCK"position during 10 seconds, and then to the"ON" position, in order to preheat again.
it to a complete stop in a safe location off theroadway.
After starting the engine, do not drive the vehi-
cle until the vacuum level is above 275 mmHgbelow atmosphere and warning light has turnedoff. If further trouble is experienced, the vehicleshould not be driven at all but taken to a dealerby a professional towing service. B265C02HP-EAT
Diesel Preheat Indication Light-amber
The indication light illuminates amber when the ignition switch is placed at the "ON" position.The engine can be started after the preheatindication light goes off. The illuminating timevaries with the water temperature.
B265A01B-EAT Fuel Filter Warning Light(Diesel Engine)
This light illuminates when the ignition switch is set to the "ON" position and goes off after theengine has started. If it lights up whilst theengine is running, it indicates that water hasaccumulated inside the fuel filter. If this hap-pens, remove the water from the fuel filter. (Refer to "Owner Maintenance") B265B01HP-GAT Brake Vacuum Warning Light(Diesel Engine)
WARNING:
If you suspect brake trouble, have your brakes checked by a Hyundai dealer as soon aspossible. Driving your car with a problem ineither the brake electrical system or brakehydraulic system is dangerous, and couldresult in serious injury or death.
The brake vacuum warning light should come onwhen the vacuum level in brake booster de-scends to about 275 mmHg or below. The brakesystem is designed to stop the vehicle withreserve assist if brake pedal is held down. Thisreserve is greatly reduced each time you releasethe brake. Without vacuum assist your vehiclecan still be stopped by pushing much harder onbrake pedal, however the stopping distance maybe much longer. If the light comes on at anyother time, you should slow the vehicle and bring
Water temperature (°F)(°C)
Below -22(-30)
-13(-25)-4(-20)
5(-15)
14(-10) 23(-5)32(0)
68(20) Illuminating time
(sec.)
26 201510
5.53.5 20