check engine Hyundai Terracan 2005 Manual Online

3 IN CASE OF EMERGENCY
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1. Ensure that the booster battery is 12
volt type. If the booster battery is installed in another vehicle, ensure that the two vehicles are not touch- ing.
2. Turn off all unnecessary electrical equipment in both vehicles.
3. Ensure that the engine of the ve- hicle providing the jump start is run- ning prior to connection of the jump cables.
4. Connect the red jump cable to the positive (+) terminal of the boosterbattery and the other end to thepositive (+) terminal of the dis- charged battery.
5. Attach the black jump cable to the negative (-) terminal of the boosterbattery, and the other end to a ground point within the engine compartmentof the vehicle with the flat bat-tery. Do not connect to the negative bat- tery terminal of the flat battery sincesparks may be generated with the subsequent risk of explosion.
6. Raise the booster vehicle engine speed to 2,000 r.p.m. and start theengine of the vehicle with the flat battery. 7. Switch "ON" the main beam
headlamps before carefully remov-ing the jumper cables in the reverse order of attachment. Once the jumper cables have been removed,switch "OFF" the main beam headlamps.
CAUTION:
If the jump cable is incorrectly in- stalled, damage to the vehicle elec- trical system may occur, in particu- lar the electronic components suchas the Fuel Injection system com- puter and the Automatic transmis- sion computer. The battery mustnever be disconnected whilst the engine is running.
IF THE ENGINE OVERHEATS
HPD040A2-E If the temperature gauge indicates overheating:
1. Pull off the road and stop as soon as it is safe to do so.
2. Place the gear selector lever in "P"
(automatic), or neutral (manual trans- mission) and set the parking brake. If the air conditioning is on, turn it off.
3. If coolant is running out under the car or steam is coming out from underthe bonnet, stop the engine. Do not open the bonnet until the coolant hasstopped running or the steaming has stopped. If there is no visible loss of coolant and no steam, leave theengine running and check to be sure the engine cooling fan is operating. If the fan is not running, turn theengine 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 satisfactory, check for coolant leaking from theradiator, hoses or under the car. (If the air conditioning had been in use, it is normal for cold water to bedraining from it).

3
IN CASE OF EMERGENCY
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!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.

5VEHICLE MAINTENANCE REQUIREMENTS
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NOTE:The inspection and testing of cer-
tain electronic fuel injection/engine management and automatic trans- mission control systems requirespecialised electronic equipment specifically designed for Hyundai vehicles. The use of general pur-pose electrical test equipment may result in damage to the control unit microprocessors.
DF020C2-E
Specified Scheduled Procedures
The specified scheduled procedures
are listed in the maintenance chartsbeginning at page 5-3. The operationsspecified must be performed at the time or mileage intervals shown irre- spective of whether the mileage inter-val has been reached before the speci- fied time interval.
Certain lubricants and components
degrade with both time and mileage(eg, engine oil and brake fluid) and therefore it is not permissable to basethe maintenance schedule upon mile- age alone. It is strongly recommended DF020F1-E
SERVICE HISTORY
It is important that all scheduled main-
tenance services are recorded in the warranty and service passport to en- sure that proof of maintenance is avail- able when warranty service is required.
that the maintenance operations areperformed by a Hyundai dealer be-cause of the need for specialized knowl- edge and tooling and to ensure that no possibility of invalidating the manufac-turers warranty exists.
The maintenance schedules relate to
vehicles operated under normal condi-tions, vehicles which are operated under adverse conditions will require more frequent maintenance which isdescribed at page 5-6. NOTE:
Service schedules may change de-
pending on individual country needs. Please ask your localHyundai dealer for a copy of the service schedule that relates to that country.MAINTENANCE AND SER- VICING REQUIREMENTS
DF020A1-E To ensure the continued reliability and safety of the vehicle, certain routine maintenance operations are requiredat specific mileage or time intervals.It is the responsibility of the vehicleowner to ensure that the maintenanceschedules shown in both this Owner's Manual and the Warranty and Service Passport are adhered to.The new vehicle warranty may beinvalidated if the routine maintenanceoperations are not performed in line with the recommendations outlined and the safety and durability of the vehicleadversely affected.It is recommended that all mainte-nance operations with the exception ofthe daily operating checks are en- trusted to a Hyundai dealer to ensure that the latest repair and maintenanceprocedures and specialized servicing tools are employed. In addition, the use of genuine Hyundai replacementparts will ensure that the vehicle safety and performance will not be compro- mised.

5
VEHICLE MAINTENANCE REQUIREMENTS
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20 24
I
R II I I
RR II I I I I I I I I I I I I I I I
F030C06HP-EAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
DESCRIPTION
GENERAL MAINTENANCE COOLING SYSTEM COOLANT COOLANT SPECIFIC GRAVITY MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION FLUID AND FILTER BRAKE PIPES, HOSES, AND CONNECTIONS BRAKE FLUID CLUTCH FLUID
REAR BRAKE LININGS, CYLINDERS AND PARKING BRAKE BRAKE PADS, CALIPERS AND ROTORS SUSPENSION AND STEERING SYSTEM FRONT SUSPENSION BALL JOINTS
STEERING GEAR BOX, LINKAGE AND BOOTS, LOWER ARM BALL JOINT, UPPER ARM BALL JOINT
DRIVE SHAFT AND BOOTS TRANSFER CASE OIL AXLE GEAR OIL CLEAN PROPELLER SHAFT/RETIGHTEN BOLTS REAR WHEEL BEARINGS TYRE CONDITION AND PRESSURE (incl. Spare) LUBRICATE LOCKS AND HINGES CHECK ALL ELECTRICAL SYSTEMS ROAD TEST CHECK ALL SYSTEMS WITH HI-SCAN CHECK EMISSIONS CHECK 4 WHEEL ALIGNMENT
NO.
1
2 3 4 5 6 7 8 9
1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25
60 72
I
RR II
R
I
RR II I I I I I I I I I I I I I I I
50 60
I I I I I I I I I I I I I I I I I I I I I I I
40 48
I
R II I I
RR II I I I I I
R I I I I I I I I I
30
36
I
R
I I I I I I I I I I I I I I I I I I I I I I
10 12
I I I I I I I I I I I I I
R I I I I I I I I I
MILES X 1000MONTHS
Petrol Engine Diesel Engine

5VEHICLE MAINTENANCE REQUIREMENTS
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ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS (FOR PETROL ENGINE) TIMING BELTBRAKE PADS, CALIPERS AND ROTORSREAR BRAKE LININGS, CYLINDERS AND PARKING BRAKESTEERING GEAR BOX, LINKAGE AND BOOTS/LOWER ARM BALL JOINT, UPPER ARM BALL JOINT DRIVE SHAFTS AND BOOTS MANUAL TRANSMISSION OILAUTOMATIC TRANSMISSION FLUID AND FILTERTRANSFER CASE OIL *1AXLE GEAR OIL *1MAINTENANCE UNDER SEVERE USAGE CONDITIONS A, B, C, F, H A, B, F, G, H, I, JC, EG, 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, JA, C, E, F, G, H, IC, E, G, H, IC, E, G, H, I
F040A05HP-EAT 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 RR
II II
R RR IEVERY 4,500 MILES OR 6 MONTHS MORE FREQUENTLY MORE FREQUENTLYEVERY 37,000 MILES OR 48 MONTHSMORE FREQUENTLYMORE FREQUENTLY MORE FREQUENTLYEVERY 9,000 MILES OR 12 MONTHS EVERY 60,000 MILESEVERY 27,000 MILESEVERY 60,000 MILESMORE FREQUENTLY
DRIVING
CONDITION
MAINTENANCE INTERVALS
MAINTENANCE
OPERATION
MAINTENANCE ITEM
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 F - More than 50% driving in heavy city traffic during hot weather above
90°F (32°C)
G - Driving in mountainous areas
H - Towing a trailer
I - Driving for patrol car, taxi, or other commercial use 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. (40 cm) deep.
PETROL ENGINE DIESEL ENGINE

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VEHICLE MAINTENANCE REQUIREMENTS
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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
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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.

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VEHICLE MAINTENANCE REQUIREMENTS
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F070C01A-AAT
o Coolant
The coolant should be changed at
the intervals specified in the mainte- nance schedule. F070D01HP-AAT
o Manual transmission oil
Inspect the manual transmission oil according to the maintenance sched- ule.
NOTE: If the oil level is low, check forpossible leaks before adding oil. Do not overfill. F070E02HP-GAT
o Automatic transmission fluid and filter
The fluid level should be in the "HOT"
range of the dipstick, after engine and transmission and filter are at normal operating temperature. Check the Au-tomatic and filter Transmission and filter Fluid level with the engine running and the transmission and filter inneutral, with the parking brake properly applied. Use MOBIL 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. Replace any deteriorated or damaged parts immediately. F070G02A-AAT o Brake fluid Check brake fluid level in the brake fluid reservoir. The level should be between "MIN" and "MAX" marks on the side of the reservoir. Use onlyhydraulic brake fluid conforming to DOT 3 or DOT 4. F070H01HP-AAT
o Rear brake linings, pad and parking brake Check the rear brake linings and pads for scoring, burning, leaking fluid, bro-ken parts, and excessive wear. In- spect the parking brake system in- cluding the parking brake lever andcables. For detailed service proce- dures, refer to the Shop Manual.

5VEHICLE MAINTENANCE REQUIREMENTS
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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 engineand listen carefully for any exhaust gas 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.
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 dam-
age. Check the dust boots and ball joints for deterioration, cracks, or dam- age. Replace any damaged parts. F070N01A-AAT
o Power steering pump, belt and hoses
Check the power steering pump and
hoses for leakage and damage. Re- place any damaged or leaking parts immediately. Inspect the power steer-ing belt for evidence of cuts, cracks, excessive wear, oiliness and proper tension. Replace or adjust it if neces-sary.
F070P01HP-AAT
o Drive shafts and boots
Check the drive shafts, boots and
clamps for cracks, deterioration, ordamage. Replace any damaged partsand, if necessary, repack the grease.
F070Q01A-AAT
o Air conditioning refrigerant
Check the air conditioning lines and
connections for leAakage and dam-age. Check air conditioning perfor- mance according to the relevant shop manual if necessary.

Engine Compartment ................................................... 6-2
Daily Operating Checks ............................................... 6-4
Engine Oil ..................................................................... 6-4
Engine Oil and Filter Replacement .............................. 6-8
Engine Coolant Checking and Replacing .................... 6-9Spark Plug................................................................... 6-12
Changing the Air Cleaner Filte r ...................................6-13
Manual Transmission Lubricant ..................................6-16
Automatic Transmission Lubricant ..............................6-17
Brake System Checking ............................................. 6-19
Checking the Clutch Fluid ........................................... 6-20
Air Conditioning System Maintenance ........................ 6-21
Checking Engine Drive Belts ...................................... 6-24
Fusible Links ............................................................... 6-25
Battery Mai ntenance ................................................... 6-27
Checking Electric Cooling Fans .................................6-28
Fuel Filter ..................................................................... 6-30
Power Steering Fluid Level ......................................... 6-29
Replacing Headlight Bulbs .......................................... 6-31
Headlight Aiming Adjustment ...................................... 6-33
Bulb Wattages ............................................................. 6-35
Fuse Panel D escription ............................................... 6-36
OWNER MAINTENANCE
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