cooling Hyundai Terracan 2006 Service Manual

3 IN CASE OF EMERGENCY
4
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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 cables are incorrectly installed, 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 broken. 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 contacts the body. People using pacemakers should ensure thatthey keep a distance of 30cm from the ECU or wiring harness within the engine room while engine is run-ning, since the high currents in the Common Rail system produce con- siderable 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 authorised repairer for assistance.
WARNING:
Do not remove the radiator cap when the engine is hot since steam and boiling water may be ejected fromthe 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 the reservoir(page 6-10) up to the baseof 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 overheatsrepeatedly, the advice of a Hyundai authorised repairer 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 authorisedrepairer.

5
VEHICLE MAINTENANCE REQUIREMENTS
5
20 24
I
R II I I
RR II I I I I I I I I I I I I I I I
R
F030C07HP-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 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 CLIMATE CONTROL AIR FILTER (FOR EVAPORATOR AND BLOWER UNIT)
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 26
60 72
I
RR II
R
I
RR II I I I I I I I I I I I I I I I
R
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
R
40 48
I
R II I I
RR II I I I I I
R I I I I I I I I I
R
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
R
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
R
MILES X 1000MONTHS
Petrol Engine Diesel Engine

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 the filter is re-placed.
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, such as radiator, coolant reservoir, hoses andconnections for leakage and damage. Replace any damaged parts.

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 .................... 6-9
Changing the Air Cleaner Filter ...................................6-12
Manual Transmission Lubricant ..................................6-15
Automatic Transmission Lubricant ..............................6-16
Brake System Checking ............................................. 6-18
Checking the Clutch Fluid ........................................... 6-19
Air Conditioning System Maintenance ........................ 6-20
Changing the Climate Control Air Filter .. ....................6-22
Checking Engine Drive Belts ...................................... 6-24
Fusible Links ............................................................... 6-25
Battery Mai ntenance ................................................... 6-27
Checking Electric Cooling Fans .................................6-29
Power Steering Fluid Level ......................................... 6-29
Fuel Filter ..................................................................... 6-30
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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6

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OWNER MAINTENANCE
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G030B06HP-EAT
Recommended Oil
1. Petrol Engine
(1) Select engine oil of the proper SAE
viscosity number according to the atmospheric temperature. Recommended viscosity is given in the following illustration. The oil viscosity should be selectedaccording to the operating environ-ment of the engine by means of the table shown above. The engine oil recommendations are complete inthemselves and the use of additives is neither required nor recommended. The use of engine oil additives may resultin invalidation of the vehicle warranty. NOTE:
o SAE 5W-20 (5W-30), ILSAC GF-3
engine oil is preferred regardless of regional option and enginevariation.
o If SAE 5W-20, ILSAC GF-3 engine
oil is not available, secondaryrecommended engine oil for cor- responding temperature range can be used.
(2) The engine oil quality should meet the following classification. API SJ, SL or ABOVE, ILSAC GF-3 or ABOVE
G030B01JM
!WARNING:
o Performing maintenance work on a vehicle can be dangerous. You can be seriously injured whilst performing some maintenanceprocedures. If you lack sufficient knowledge and experience or the proper tools and equipment to dothe work, have it done by Hyundai authorised repairer.
o Working under the bonnet with the engine running is dangerous. It becomes even more dangerouswhen you wear jewellery or loose clothing. These can become en- tangled in moving parts and re-sult in injury. Therefore, if you must run the engine whilst work- ing under the bonnet, make cer-tain that you remove all jewellery (especially rings, bracelets, watches, and necklaces) and allneckties, scarves, and similar loose clothing before getting near the engine or cooling fans.

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OWNER MAINTENANCE
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G350A01A-EAT
ENGINE OIL CONSUMPTION Function of engine oil
Engine oil has the primary function of
lubricating and cooling the inside of the engine.
HPG030C2-E
ENGINE OIL REPLENISHMENT
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. Engine oil consumption It is normal that an engine should consume some engine oil in the course of normal driving.The causes of oil consumption in anormal engine are as follows;
o Engine oil is used to lubricate pis-
tons, piston rings and cylinders. A thin film of oil is left on thecylinder wall when a piston movesdownwards in the cylinder.High negative pressure generatedduring engine operation sucks some of this oil into the combustion cham- ber.This oil with some oil of the cylin-der wall is burned by the high tem-perature combustion gases during the combustion process.
o The engine oil consumption is strongly effected by the viscosityand quality of oil, engine rpm and driving condition etc.More engine oil may be consumedunder severe driving conditionssuch as high speeds, frequent ac- celeration and deceleration, com- pared to normal driving.
HHP5003
G030D01HP
Petrol Engine
Diesel Engine!
To add oil to the engine, remove the filler cap by rotating in an counter-clockwise direction and pour engine oil into the engine. Before checking the level again, allow several minutesfor the oil to drain into the sump. Replace the oil filler cap rotating it in a clockwise direction until tight. The quantity of oil required to raise the level from the minimum to maximum level is approximately 1 litre (PetrolEngine)/1.4 litres (Diesel Engine).
WARNING:
Be very careful not to touch the
radiator hose when adding the en-gine oil as it may be hot enough toburn you.

6
OWNER MAINTENANCE
9
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engine and ensure that no oil leaks exist. Turn off the engine and aftera couple minutes, recheck the oil level.
CAUTION:
Slowly pour the recommended oil by using a funnel. Do not overfill to prevent engine damage.
WARNING:
Prolonged and repeated contact withused engine oils may result in seri- ous skin disorders including der-matitis and cancer. Avoid contact with skin as far as possible and always wash thoroughly after anycontact. Keep used oils out of reach of children. It is illegal to pollute drains, water courses and soil. Useonly authorisedwaste collection fa- cilities including civic amenity sites and garages for the disposalof used oil and oil filters. If in doubt, contact the local authority for dis- posal instructions. WARNING:
Do not remove the radiator cap when
the engine is hot, since the system is pressurised and coolant may be ejected from the radiator resultingin scalding.
SG050B1-E
Coolant recommendations
Only ethylene glycol based coolant
with a corrosion inhibitor suited toaluminium alloy engine componentsshould be used in the cooling system. No further additives or inhibitors should be used. The coolant specificgravity should be checked as pre- scribed in the maintenance schedule to ensure adequate frost and corro-sion protection. In addition, the en- gine coolant must be replaced at the specified interval since the corrosioninhibitor properties deteriorate with time.
ENGINE COOLANT CHECK- ING AND REPLACING
SG050A1-E
! It is important to note that whilst an increase in the concentration of antifreeze gives an increase in the level of frost protection, a solution which is in excess of 65% anti freeze will resultin reduced frost protection and engine overheating. Therefore the recom- mended concentration of 50% shouldnot be exceeded for general use.The use of methanol based anti freezecompounds may result in engine over-heating and will invalidate the vehicle warranty. NOTE: It is imperative that vehicles fitted with an air conditioning systemhave a coolant concentration of the recommended strength at all times. The use of the air condition-ing system when the cooling sys- tem is filled with water only will result in the heater matrix freezingand subsequently bursting.

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OWNER MAINTENANCE
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3. With the heater temperature control set to the "HOT" position, remove the radiator cap and open the radia-tor drain tap. 4. When the engine coolant has drained
completely, close the drain tap en-suring that this is not over tight- ened.
5. Prepare a suitable quantity of new engine coolant (refer to section 9)and pour this into the radiator.
6. Start the engine with the radiator cap still removed and continue to add coolant as the level decreases as air is expelled from the system. When the level remains constant,replace the radiator cap and replen- ish the coolant reservoir.
7. When the engine is hot, check to ensure that no coolant leaks are present.
G050D01HP-D
HHP5006-E
HHP5008
Petrol EngineDiesel Engine
!WARNING:
The cooling fan is controlled by engine coolant temperature and maysometimes operate even when the engine is not running. Use extreme caution when working near theblades of the cooling fan so that you are not injured by a rotating fan blade. As the engine coolant tem-perature decreases, the fan will au- tomatically shut off. This is a nor- mal condition.

6 OWNER MAINTENANCE
18
!
!!WARNING (Diesel only):
Never work on injection system with
engine running or within 30 sec- onds after shutting off engine. Highpressure pump, rail, injectors and high pressure pipes are subject to high pressure even after the enginestopped. The fuel jet produced by fuel leaks may cause serious injury, if it contacts the body. People usingpacemakers should ensure that they keep a distance of 30cm from the ECU or wiring harness within theengine room whilst engine is run- ning, since the high currents in the Common Rail system produce con-siderable magnetic fields.
WARNING:
The electric engine cooling fan au-
tomatically switches on and off ac- cording to engine temperature. Be careful to keep away from the fanduring this check as it may switch on at any time.
NOTE: Only lint free cloth should be used
for wiping the dipstick. The pres- ence of lint within the transmis- sion may cause problems with the normal function of the transmis-sion. CAUTION:
Correct operation of the braking
system is essential to the safe op- eration of the vehicle and there- fore, any maintenance operationsother than those listed below should be entrusted to a Hyundai authorised repairer.
SG120C2-E
Brake Fluid Recommendations
Only brake fluid conforming to DOT 3
or DOT 4 specifications or highermay be used in the braking system. Care should be taken to observe the instructions and precautions printedupon the container.
BRAKE SYSTEM CHECKING
SG120A1-E