automatic Hyundai Terracan 2005 Workshop Manual

5VEHICLE MAINTENANCE REQUIREMENTS
8
A, B, C, D, E, F, G, H, I, K A, B, F, G, H, I, JC, E G, H, I, JD, E, F, GC, D, E, G, H, I C, D, E, G, H, I C, D, E, F C, D, E, F A, C, D, E, F, G, H, I, J A, C, E, F, G, H, I C, E, G, H, I C, E, G, H, I C,E
ENGINE OIL AND FILTER (Gasoline Engine) ENGINE OIL AND FILTER (Diesel Engine (2.5 TCI))ENGINE OIL AND FILTER(Diesel Engine (2.9 CRDi))AIR CLEANER FILTERSPARK PLUGS (For Gasoline Engine) TIMING BELT BRAKE PADS, CALIPERS AND ROTORSREAR BRAKE DRUMS/LININGS, PARKING BRAKESTEERING GEAR BOX, LINKAGE AND BOOTS/LOWER ARM BALL JOINT, UPPER ARM BALL JOINTDRIVE SHAFTS AND BOOTS MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSIONFLUIDTRANSFER CASE OIL *
1
AXLE GEAR OIL * 1
AIR CONDITIONER FILTER (For Evaporator and Blower Unit)
European Community Only Except European Community
F040A07HP-GAT 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
R R R R
I I I I
RRR RR
EVERY 7,500 KM OR 6 MONTHS EVERY 4,000 KM EVERY 3,000 KMEVERY 7,500 KM OR 6 MONTHSEVERY 5,000 KM OR 6 MONTHSMORE FREQUENTLYMORE FREQUENTLY EVERY 60,000 KM OR 48 MONTHS MORE FREQUENTLYMORE FREQUENTLY MORE FREQUENTLY EVERY 15,000 KM OR 12 MONTHS EVERY 100,000 KMEVERY 45,000 KM EVERY 40,000 KM EVERY 100,000 KMMORE FREQUENTLYMORE FREQUENTLY
SEVERE DRIVING CONDITIONS
A - Repeatly driving short distance of less than 8km(5miles) in normal temperature or less than 16km(10miles) in freezing temperature
B - Extensive engine idling or low speed driving for long distances
C - Driving on rough, dusty, muddy, unpaved, graveled or salt- spread roads
D - Driving in areas using salt or other corrosive materials or in very
cold weather
DRIVING
CONDITION
MAINTENANCE INTERVALS
MAINTENANCE
OPERATION
MAINTENANCE ITEM
E - Driving in sandy areas
F - Driving in heavy traffic area over 32°C(90°F)
G - Driving on uphill, downhill, or mountain road
H - Towing a Trailer, or using a camper, or roof rack
I - Driving as a patrol car, taxi, other commercial use or vehicle towing
J - Driving over 170 Km/h(100 MPH)
K - Frequently driving in stop-and-go conditions
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
European Community Only Except European Community Europe Countries Only Except Europe Countries
*1: Transfer Case Oil and Axle Gear Oil should be checked (and replaced if necessary) anytime they have been submerged in water
over 40cm (15.7 in.) deep.

5
VEHICLE MAINTENANCE REQUIREMENTS
11
F070E03HP-GAT
o Automatic Transmission Fluid
The fluid level should be in the "HOT" range of the dipstick, after the engine and transmission are at normal operat- ing temperature. Check the automatictransmission fluid level with the engine running and the transmission in neu- tral, with the parking brake properlyapplied. Use MOBIL DEXRON-II when adding or changing fluid.
F070D01A-AAT
o Manual Transmission Oil
Inspect the manual transmission oil according to the maintenance sched- ule.
NOTE: If the oil level is low, check for possible leaks before adding oil. Donot overfill. F070F01A-AAT
o Brake Hoses and Lines
Visually check for proper installation,
chafing, cracks, deterioration and any leakage. Replace any deteriorated or damaged parts immediately.
F070G02A-AAT
o Brake Fluid
Check brake fluid level in the brake
fluid reservoir. The level should bebetween "MIN" and "MAX" marks on the side of the reservoir. Use only hydraulic brake fluid conforming to DOT3 or DOT 4.
F070H01A-AAT
o Rear Brake Drums/ Linings
Parking Brake
Check the rear brake drums and lin-
ings for scoring, burning, leaking fluid,broken parts, and excessive wear. In-spect the parking brake system in- cluding the parking brake lever 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 cali- pers for fluid leakage. F070K01A-AAT o Exhaust Pipe and Muffler Visually inspect the exhaust pipes, muffler and hangers for cracks, dete- rioration, or damage. Start the engine and listen carefully for any exhaustgas leakage. Tighten connections or replace parts as necessary. F070L01A-AAT o Suspension Mounting Bolts Check the suspension connections for looseness or damage. Retighten to the specified torque.

Engine Compartment ................................................... 6-2
General Checks ........................................................... 6-5
Checking the Engine Oil .............................................. 6-6
Changing the Engine Oil and Filter ..........................6-10
Checking and Changing the Engine Coolant ........... 6-11
Spark Plugs ................................................................ 6-14
Changing the Air Cleaner Filter ................................ 6-15
Checking the Transmission Oil (Manual) .................. 6-18
Checking the Transmission Fluid (Automatic) .......... 6-20
Checking the Brakes ................................................. 6-22
Checking the Clutch Fluid ......................................... 6-24
Air Conditioning Care ................................................ 6-24
Changing the Air Conditioner Filter .......................... 6-26
Checking Drive Belts ................................................. 6-29
Checking and Replacing Fuses ................................ 6-30
Checking The Battery ................................................ 6-32
Checking The Eclectric Cooling Fans ....................... 6-34
Power Steering Fluid Level ....................................... 6-34
Fuel Filter ................................................................... 6-35
Replacement of Headlight Bulbs ............................... 6-39
Headlight Aiming Adjustment .................................... 6-40
Bulb Wattages ............................................................ 6-43
Fuse Panel Description ............................................. 6-44
DO-IT-YOURSELF MAINTENANCE
6
6

6 DO-IT-YOURSELF MAINTENANCE
2
1. Fuse and Relay Box
2. Battery
3. Engine Cover
4. Brake Fluid Reservoir
5. Power Steering Fluid Reservoir 6. Windshield Washer Fluid Reser-
voir
7. Air Cleaner Filter
8. Radiator Cap
9. Engine Oil Filler Cap 10.Automatic Transmission Fluid
Level Dipstick (Vehicle With Auto- matic Transmission)
11.Engine Oil Level Dipstick
12.Engine Coolant Reservoir Cap G010A01HP
G010A01HP-GAT Gasoline Engine (3.5 V6)
CAUTION:
When inspecting or servic-
ing the engine, you should handle tools and other heavy objects carefully so that the plastic cover of theengine is not damaged.
!
ENGINE COMPARTMENT

6
DO-IT-YOURSELF MAINTENANCE
3
G010B01HP-GAT
Diesel Engine (2.5 TCI)
G010B01HP
1. Fuse and Relay Box
2. Battery
3. Automatic Transmission Fluid Level Dipstick (Vehicle With Auto- matic Transmission)
4. Engine Oil Filler Cap 5. Engine Oil Level Dipstick
6. Engine Cover
7. Brake Fluid Reservoir
8. Clutch Fluid Reservoir (If Installed)
9. Power Steering Fluid Reservoir
10.Windshield Washer Fluid Reser-
voir
11.Air Cleaner Filter
12.Radiator Cap
13.Fuel Filter
14.Engine Coolant Reservoir Cap CAUTION:
When inspecting or servic- ing the engine, you shouldhandle tools and other heavy objects carefully so that the plastic cover of theengine is not damaged.
!

6 DO-IT-YOURSELF MAINTENANCE
4
1. Fuse and Relay Box
2. Battery
3. Engine Oil Level Dipstick
4. Engine Cover
5. Engine Oil Filler Cap 6. Brake Fluid Reservoir
7. Windshield Washer Fluid Reser-
voir
8. Air Cleaner Filter
9. Radiator Cap 10.Automatic Transmission Fluid
Level Dipstick (Vehicle With Auto-matic Transmission)
11.Fuel Filter
12.Power Steering Fluid Reservoir
13.Engine Coolant Reservoir Cap G010C01HP
G010C01HP-GAT Diesel Engine (2.9 CRDi)
CAUTION:
When inspecting or servic-
ing the engine, you should handle tools and otherheavy objects carefully so that the plastic cover of the engine is not damaged.
!

6
DO-IT-YOURSELF MAINTENANCE
5GENERAL CHECKS
G020A01HP-GAT
Engine Compartment
The following should be checked regu- larly:
o Engine oil level and condition
o Transmission fluid level and condi- tion
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) o Defroster, heating system opera-
tion (and air conditioning, if in- stalled)
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, in-
cluding clutch operation
o Automatic transmission operation, including "Park" mechanism opera-tion
o Seat control condition and opera-
tion
o Seat belt condition and operation
o Sun visor operation If you notice anything that does not operate correctly or appears to be functioning incorrectly, inspect it care- fully and seek assistance from yourHyundai dealer if service is needed.
G020C01HP-GAT
Vehicle Interior
The following should be checked each
time when the vehicle is driven:
o Lights operation
o Windshield wiper operation
o Horn operation

6 DO-IT-YOURSELF MAINTENANCE
14SPARK PLUGS
!
G060A01HP-GAT
(Gasoline Engine Only)
Your engine was originally equipped
with platinum-tipped spark plugs.
Platinum-tipped spark plugs will last
longer than conventional type spark plugs and can be identified by blue lines on the ceramic shell.
NOTE: Do not clean or regap platinum-
tipped spark plugs.
Unleaded: 1.0 ~ 1.1mm Leaded : 0.7 ~ 0.8mm
Type
RC10PYPB4 (CHAMPION) PFR5N-11 (NGK) RC10YC(CHAMPION)BKR5ES (NGK)
G060B01HP-AAT
Replacing the Spark Plugs
The spark plugs should be changed
at the intervals specified in the ve- hicle maintenance schedule in Sec- tion 5 or whenever engine perfor-mance indicates they should be changed. Symptoms that suggest poor spark plug performance include en-gine misfiring under load, loss of fuel economy, poor acceleration, etc.
When spark plugs are replaced, al-
ways use spark plugs recommended by Hyundai. The use of other sparkplugs can result in loss of perfor- mance, radio interference or engine damage. Recommended Spark Plugs:Remark Unleaded* Leaded
*: Platinum coated
6. Start the engine, top off the radia- tor with water and then add coolant to the reservoir until the level is between "LOW" and "FULL".
7. Replace the radiator and reservoir caps and check to be sure thedrain cocks are fully closed and not leaking.
WARNING:
The cooling fan is controlled byengine coolant temperature and may sometimes operate even when the engine is not running. Useextreme caution when working near the blades of the coolant fan so that you are not injured by a rotat-ing fan blade. As the engine cool- ant temperature decreases, the fan will automatically shut off. This isa normal condition. G060A01L

6 DO-IT-YOURSELF MAINTENANCE
20CHECKING THE TRANSMIS- SION FLUID (AUTOMATIC)
!
G110B02HP-GAT
Recommended Fluid
Your Hyundai automatic transmission
is specially designed to operate with MOBIL DEXRON-II. Damage caused by a nonspecified fluid is not coveredby your new vehicle limited warranty.
G110C03HP-GAT
Transmission Fluid Capacity
The fluid capacity of the automatic
transmission is;
WARNING:
The transmission fluid level should
be checked when the engine is at normal operating temperature. This means that the engine, radiator,exhaust system etc., are very hot. Exercise great care not to burn yourself during this procedure. G110D02HP-GAT
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 should be atnormal operating temperature and the engine idling.
While the engine is idling, apply the
brakes and move the gear selector lever from "P" to each of its other positions — "R", "N", "D", "2", "L" — and then return to "N" or "P". With theengine still idling:
G110A02HP-AAT Transmission fluid in the automatic
transmission should be checked at those intervals specified in the ve-hicle maintenance schedule in Sec- tion 5.
NOTE: Automatic transmission fluid is
basically a red color. As driving distance increases, the fluid color turns darkish red gradually. It is normal condition and you shouldnot judge the need to replace based up on the changing color.
You must replace the automatic
transmission fluid in accordancewith intervals specified in the ve- hicle maintenance schedule in sec-tion 5.
Engine GasolineDiesel (2.9 CRDi)Diesel (2.5 TCI) Capacity
10.5 liters11.8 liters 8.2 liters
HHP3018

6 DO-IT-YOURSELF MAINTENANCE
22CHECKING THE BRAKES
!
G120A01A-AAT
CAUTION:
Because brakes are essential to the safe operation of the car, it issuggested that they be checked and inspected by your Hyundai dealer. The brakes should bechecked and inspected for wear at those intervals specified in the vehicle maintenance schedule inSection 5.!!WARNING:
The cooling fan is controlled by engine coolant temperature and may sometimes operate even whenthe engine is not running. Use extreme caution when working near the blades of the cooling fan, sothat you are not injured by a rotat- ing fan blade. As the engine cool- ant temperature decreases, the fanwill automatically shut off. This is a normal condition. 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 aresubjected to high pressure even after the engine has been switched off. The fuel jet produced by fuelleaks may cause serious injury, if it contacts with the body. People using pacemakers should notmove closer than 30cm to the ECU or wiring harness within the en- gine room with the engine run-ning, since the high currents in the Common Rail system produce considerable magnetic fields.