ECU Hyundai Terracan 2005 Service Manual

1
CONTROLS AND EQUIPMENT
81
If your Hyundai has roof bars fitted, you can load cargo / luggage on top of these. The two roof bars (1) can be repositioned forward and rearward forconveniently loading cargo / luggage on to them. With an assistant on the opposite side of the vehicle, press andhold the slider lock buttons (2) on each side, then move the roof bar to the correct location.The roof bars automatically lock in the locating hole when the slider lock but- tons are released.ROOF BARS
B630A01HP-EAT (Not all models)
HHP2181
1
2
o Always drive your vehicle at a
moderate speed.
o Loading cargo or luggage over specification on the roof bars may damage stability of your ve- hicle.! CAUTION:
o The roof bars should be posi- tioned before securing a load to them.
o If a sunroof is fitted, do not posi-
tion the roof bar loads whichcould interfere with the opening of the sunroof.
o The following specifications are recommended when loadingcargo or luggage.
o Loading cargo or luggage above 75 lb (34 kg) on the roof bars may damage your vehicle. When you carry large objects,never let them hang over the rear or the sides of your vehicle.
o To prevent damage or loss of cargo as you are driving, checkfrequently to make sure the lug- gage carrier and cargo are stillsecurely fastened.
ROOF BARS 75 lb (34 kg) EVENLY DISTRIBUTED

2 DRIVING YOUR HYUNDAI
26
YC200B2-E Trailer Towbars Select the correct towbar and ball com- bination, making sure that its location is compatible with that of the trailer or vehicle being towed.Use a quality non-equalizing towbar which distributes the nose weight uni- formly throughout the chassis. The towbar should be bolted securely to the car and installed by a qualifiedtechnician.
!
o The formation of snow or ice build
up inside the wheel arches may interfere with the roadwheels or steering mechanism. In such in- stances, unusual noises or an in-crease in steering effort may re- sult. Therefore, ensure that the wheelarches are checked peri-odically and any accumulated snow or ice removed.
o It is advisable to carry emergency equipment including, torch,shovel, tow rope, blankets etc., if a journey is to be undertakeninto areas of severe road condi- tions. CAUTION:
Do not do any towing with your carduring its first 1,000 miles in order to allow the engine to have properlyrun-in. Failure to heed this caution may result in serious engine or trans- mission damage.
TRAILER OR VEHICLE TOWING
HPC200A2-E If you are considering towing with your car, you should first check with your Local Laws to determine their legal requirements.Since laws vary from county to county, the requirements for towing trailers, cars, or other types of vehicles orapparatus may differ. Ask your Hyundai dealer for further details before towing.

2 DRIVING YOUR HYUNDAI
30
14. When going down a hill, shift into alower gear and use the engine brak- ing effect. When ascending a long grade, downshift the transmission to alower gear and reduce speed to reduce chances of engine over- loading and/or overheating.
15.If you have to stop whilst going uphill, do not hold the vehicle inplace by pressing on the accelera-tor. This can cause the automatic transmission to overheat. Use the parking brake or footbrake.
NOTE: When towing, check transmission fluid more frequently.
HPC200E1-E Trailer or Vehicle Towing Tips
1. Before towing, check towbar and
safety cable connections as well as proper operation of the trailer run- ning lights, brake lights, and turn signals.
2. Always drive your vehicle at a mod- erate speed (Less than 60 MPH).
3. Trailer towing requires more fuel than normal conditions.
4. To maintain engine braking effi-
ciency and electrical charging per-formance, do not use fifth gear (manual transmission).
5. Always secure items in the trailer to prevent load shift whilst driving.
6. Check the condition and air pres-
sure of all tyres on the trailer and your car. Low tyre pressure can seriously affect the handling. Also check the spare tyre.
7. The vehicle/trailer combination is more affected by crosswind andbuffeting.When being passed by a large ve- hicle, keep a constant speed and steer straight ahead. If there is toomuch wind buffeting slow down to get out of the other vehicle's air turbulence. 8. When parking your car and trailer,
especially on a hill, be sure to followall the normal precautions. Turn your front wheel into the curb, set the parking brake firmly, and putthe transmission in 1st or Reverse (manual) or Park (automatic). In addition, place wheel chocks at eachof the trailer's tyres.
9. If the trailer has electric brakes,
start your vehicle and trailer mov-ing, and then apply the trailer brake controller by hand to be sure the brakes are working. This lets youcheck your electrical connection at the same time.
10.During your trip, check occasion- ally to be sure that the load issecure, and that the lights and any trailer brakes are still working.
11.Avoid jerky starts, sudden accel- eration or sudden stops.
12.Avoid sharp turns and rapid lane changes.
13.Avoid holding the brake pedal down
too long or too frequently. This couldcause the brakes to overheat, re- sulting in reduced braking efficiency.

3
IN CASE OF EMERGENCY
5
!
!
!WARNING:
Whilst the engine is running, keep hands and clothing away from mov- ing parts such as the fan and drive belts to prevent injury.
WARNING (Diesel only):
Never work on injection system withengine running or within 30 seconds after shutting off engine. High pres- sure pump, rail, injectors and highpressure pipes are subject to high pressure even after the engine stopped. The fuel jet produced byfuel leaks may cause serious in- jury, if it touch the body. People using pacemakers should not movethan 30cm closer to the ECU or wiring harness within the engine room while engine is running, sincethe 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 theengine immediately and call the near- est Hyundai dealer for assistance.
WARNING:
Do not remove the radiator cap when the engine is hot since steam andboiling water may be ejected from the radiator resulting in burns or scalding.
6. If the cause of the overheating can- not be found, wait until the engine temperature has returned to normal.Then, if coolant has been lost, care- fully remove the radiator cap and add water to bring the fluid level in thereservoir(page 6-10) up to the base of the radiator fill opening. Fill the coolant expansion tank to the half-way mark.
7. Proceed with caution until it is estab-
lished that the engine is operatingnormally. If the engine overheats repeatedly, the advice of a Hyundai dealer should be sought.! 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.

3
IN CASE OF EMERGENCY
7
!
5. Remove the lift plate from the centre
of the spare tyre after the spare tyre is lowered completely.
Installation is the reverse order of re-moval.
CAUTION:
When installing, turn the wheel nutwrench clockwise till you hear the crackle once or twice(Tighteningtorque : 3.87 kg·m). And make sure the spare tyre is secured in the proper location. It is of the utmost importance that care is exercised when changing road wheels. Ensure that the parking brakeis set and that the gear shift lever is in reverse (P, if the vehicle has automatic transmission).
HHP4026
IN THE EVENT OF A PUNC- TURE
SD060A1-E If a puncture occurs whilst driving the vehicle:
1. Bring the car to rest as soon as it is
safe to do so and with the minimum amount of braking required which will assist in maintaining the maxi-mum amount of control. The vehicle should be parked wherever pos- sible upon firm level ground to facili-tate wheel changing.
2. If the vehicle is creating a hazard
and the road conditions do not per-mit the wheel to be changed safely, assistance should be sought.
3. Passengers must not be allowed to remain inside the vehicle duringwheel changing. If a puncture oc- curs whilst the vehicle is on amotorway, the passengers should take refuge on the motorway em- bankment to avoid the possibility ofinjury occurring should the vehicle be struck by other motorway traffic.
4. Wheel changing should be per- formed according to the followinginstructions.CHANGING A FLAT TYRE
HPD070A2-E
D060A01HP

3 IN CASE OF EMERGENCY
14
!
CAUTION:
Your car can be damaged if towed incorrectly! If your car has to be towed, it should be done by your Hyundai dealer or a com- mercial tow truck service. This will help assure that your car is not damaged intowing. Also, professionals are gener- ally aware of local laws governing tow- ing. In any case, rather than risk dam-age to your car, it is suggested that you show this information to the tow truck operator. Be sure that a safety cablesystem is used and that all current laws associated with vehicle towing are ob- served. D080B01HP-EAT Towing a Car With Manual Trans- mission
D060J02O-EAT AFTER CHANGING WHEELS If you have a tyre gauge, remove the valve cap and check the air pressure.If the pressure is lower than recom- mended, drive slowly to the nearest service station and inflate to the cor-rect pressure. If it is too high, adjust it until it is correct. Always reinstall the valve cap after checking or adjustingtyre pressure. If the cap is not re- placed, air may leak from the tyre. If you lose a valve cap, buy another andinstall it as soon as possible. After you have changed wheels, al- ways secure the flat tyre in its placeand return the jack and tools to their proper storage locations.
HHP5019
IF YOUR CAR MUST BE TOWED
HHP4031
D080A02A-EAT
o Not OK for 4WD
(OK for Part-Time 4WD in 2H Position)
o OK for Manual Transmission Equipped Vehicle
D080B02HP
D080B01HP
o Not OK for 4WD (OK for Part-Time 4WD in 2H Position)
o OK for Manual Transmission Equipped Vehicle

5
VEHICLE MAINTENANCE REQUIREMENTS
7
!
F060B01A-AAT
o Drive belts
Inspect all drive belts for evidence of cuts, cracks, excessive wear or oil and replace if necessary. Drive beltsshould be checked periodically for proper tension and adjusted as neces- sary. F060C01A-AAT
o Fuel filter
A clogged filter can limit the speed at
which the vehicle may be driven, dam- age the emission system and cause hard starting. If an excessive amountof foreign matter accumulates in the fuel tank, the filter may require re- placement more frequently. After installing a new filter, run the
engine for several minutes, and checkfor leaks at the connections. Fuel fil- ters should be installed by trained technicians.
F060D01TB-AAT
o Fuel lines, fuel hoses and con- nections
Check the fuel lines, fuel hoses and
connections for leakage and damage. Have a trained technician replace anydamaged or leaking parts immediately. WARNING (Diesel only):
Never work on injection system withengine running or within 30 sec-onds after shutting off engine. High pressure pump, rail, injectors and high pressure pipes are subject tohigh 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 wiringharness within the engine room while engine is running, since the high currents in the Common Railsystem produce considerable mag- netic fields.
EXPLANATION OF SCHED- ULED MAINTENANCE ITEMS
F060M01A-AAT
o Engine oil and filter
The engine oil and filter should be
changed at the intervals specified in the maintenance schedule. If the car is being driven in severe conditions,more frequent oil and filter changes are required.

5VEHICLE MAINTENANCE REQUIREMENTS
8
F060E01A-AAT
o Timing belt Inspect all parts related to the timing belt for damage and deformation. Replace any damaged parts immedi- ately. F060G01A-EAT
o Vapour hose and fuel filler cap The vapour hose and fuel filler cap should be inspected at those intervals specified in the maintenance sched-ule. Make sure that a new vapour hose or fuel filler cap is correctly replaced. F060F02A-AAT
o Crankcase ventilation hoses
Inspect the surface of hoses for evi-
dence of heat and/or mechanical dam-age. Hard and brittle rubber, cracking, tears, cuts, abrasions, and excessiveswelling indicate deterioration. Particu- lar attention should be paid to examine those hose surfaces nearest to highheat sources, such as the exhaust manifold.
Inspect the hose routing to assure that
the hoses do not come in contact with any heat source, sharp edges or mov-ing component which might cause heat damage or mechanical wear. Inspect all hose connections, such as clampsand couplings, to make sure they are secure, and that no leaks are present. Hoses should be replaced immedi-ately if there is any evidence of dete- rioration or damage. F060H01A-AAT
o Air cleaner filter
A Genuine Hyundai air cleaner filter is
recommended when filter is replaced.
F060J01A-EAT
o Spark plugs (For petrol engine)
Make sure to install new spark plugs
of the correct heat range. F070B01A-AAT
o Cooling system
Check the cooling system part, such as radiator, coolant reservoir, hosesand connections for leakage and dam- age. Replace any damaged parts.

6 OWNER MAINTENANCE
8
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The engine oil and filter must be changed at the time or mileage intervalspecified in the maintenance sched- ule. If the vehicle is operated under severe or adverse conditions, the oil and filter must be replaced more fre-quently.
To replace the oil and filter, proceed as
follows:
1. Ensure that the engine is at normal
operating temperature and park the vehicle on level ground with the parking brake securely applied 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 re-move the drain plug from the sump. 4. When the oil has drained from the
sump, replace the drain plug using anew washer ensuring that the plug is not over tightened.
Tightening torque : 3.5 ~ 4.5 kgf.m
5. Remove the oil filter by rotating counterclockwise, using a propri- etary oil filter removal tool if neces- sary. Note that the oil filter will contain approximately 0.5 litres ofoil and this should be collected in a suitable receptacle.
6. Install a new oil filter having smeared the sealing ring with cleanoil and rotating clockwise until the filter contacts the mounting andthen a further one half turn. Do not over-tighten. Tightening torque: Petrol Engine - 1.2 ~ 1.6 kgf.m Diesel Engine - 2.3 ~ 2.5 kgf.m
7. Remove the engine oil level dipstick.
8. Pour the specified quantity of the recommended oil into the engine and replace the filler cap. Start the
CAUTION:
The oil being drained from the en-
gine will be hot. Care should be exercised to prevent scalding.
ENGINE OIL AND FILTER REPLACEMENT
G040A02HP-EAT
G040A01HP
Petrol Engine
Oil filter
Drain plug Oil filler cap
HHP5004
Diesel Engine
Oil filler capOil filter
Drain plug

6
OWNER MAINTENANCE
17
To Check the Transmission Oil Level
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 itwith your fingers. 2. Use your finger to feel inside the
hole. The oil level should be at itsbottom edge. If it is not, check for leaks before adding oil. To refill the transmission or bring the oillevel up, add oil slowly until it reaches the proper level. Do not overfill.
3. Replace the bolt and washer, screw it in with your fingers and thentighten securely with the wrench.
G100B01L
AUTOMATIC TRANSMIS- SION LUBRICANT
G110A04HP-EAT Transmission lubricant should be changed at those intervals specified in the vehicle maintenance schedulein Section 5. NOTE: Basically automatic transmission fluid is red color. As driving dis- tance increases, the fluid colorturns darkish red gradually. It is normal condition and you should not use fluid color as a criterionfor replacing the transmission fluid. You must replace the automatic transmission fluid in accordance with intervals specified in the ve- hicle maintenances schedule insection 5. Recommended Lubricant Use only MOBIL DEXRON-II. Dam- age caused by a nonspecified fluid is not covered by your new vehicle lim-ited warranty.