maintenance HYUNDAI TUCSON 2009 Service Manual

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G190A01GK
DOHC CVVT V6
Water Pump Pulley
0.2~0.24 in.
(5~6 mm)
Power steering
COMP
Auto
tensioner
Alternator Pulley
Crankshaft PulleyAlternator
Eng.pulley
CHECKING DRIVE BELTSDrive belts should be checked periodi-
cally for proper tension and adjusted if
necessary. At the same time, belts should
be examined for cracks, wear, fraying or
other evidence of deterioration and re-
placed if necessary.
Belt routing should also be checked to be
sure there is no interference between the
belts and other parts of the engine. After a
belt is replaced, the new belt should be
adjusted again after two or three weeks to
eliminate slack resulting from initial stretch-
ing after use.G190A01A-AAT
G180A01L
G160A01HR
CHECKING BRAKE PEDAL
CLEARANCEG180A01A-AATYou need a helper to check the brake
pedal clearance. With the engine running,
have your helper press down on the brake
pedal several times and then hold it down
with a force of about 110 lbs (50 kg, 490 N).
The brake pedal clearance is the distance
from the top surface of the brake pedal to
the asphalt sheeting under the floor mat.
If the brake pedal clearance is not within
the limits specified in the illustration, have
it inspected by your Hyundai dealer and
adjusted or repaired if necessary.
2.95 in. (75 mm)
G170A01A-AATBRAKE PEDAL FREE PLAYWith the engine off, press down on the
brake pedal several times to reduce the
vacuum in the brake booster.
Then, using your hand, press down slowly
on the brake pedal until you feel a change
in resistance. This is the brake pedal free-
play.
The free-play should be within the limits
specified in the illustration above. If it is not,
have it inspected by your Hyundai dealer
and adjusted or repaired if necessary.
0.12 ~ 0.31 in.
(3 ~ 8 mm)

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CHECKING AND REPLACING
FUSES
!
G200B02JM-AATReplacing Accessory Fuses
CAUTION:
When replacing a fusible link, never use
anything but a new fusible link with the
same or lower amperage rating. Never
use a piece of wire or a higher-rated
fusible link. This could result in serious
damage and create a fire hazard.
The fuse box for the lights and other elec-
trical accessories will be found on the left
side of crash pad. Inside the box you will
find a list showing the circuits protected by
each fuse.
If any of your car's lights or other electrical
accessories stop working, a blown (open)
fuse could be the reason. If the fuse has
opened, you will see that the metal strip
inside the fuse has melted through. If you
suspect a blown fuse, follow this proce-
dure:
G200A03A-AATReplacing a Fusible LinkA fusible link will melt if the electrical cir-
cuits from the battery are ever overloaded,
thus preventing damage to the entire wir-
ing harness. (This could be caused by a
short in the system drawing too much cur-
rent.) If this ever happens, have a Hyundai
dealer determine the cause, repair the
system and replace the fusible link. The
fusible links are located in a relay box in the
engine compartement for easy inspection.
HJM4002
G200A01JM
Open-
ReplaceGood

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G200B02L
!
4. Replace the blown fuse by pressing a
new fuse of the same rating into place.
The fuse should be a snug fit. If it is not,
have the fuse clip repaired or replaced
by a Hyundai dealer. If you do not have
a spare fuse, you may be able to borrow
a fuse of the same or lower rating from
an accessory you can temporarily get
along without (the radio or cigarette
lighter, for example). Always remember
to replace the borrowed fuse.
CAUTION:
An open fuse indicates that there is a
problem in the electrical circuit. If you
replace a fuse and it blows as soon as the
accessory is turned on, the problem is
serious and should be referred to a
Hyundai dealer for diagnosis and repair.
Never replace a fuse with anything ex-
cept a fuse with the same or a lower
amperage rating. A higher capacity fuse
could cause damage and create a fire
hazard.NOTE:See page 6-35 for the fuse panel descrip-
tions.
GoodOpen-Replace
1. Turn off the ignition and all other
switches.
2. Open the fuse box and examine each
fuse. Remove each fuse by pulling it
toward you (a small "fuse puller" tool is
contained in the relay and fuse box of
the engine room to simplify this opera-
tion).
3. Be sure to check all other fuses even if
you find one that appears to have
opened.
G200B01JM

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CHECKING THE BATTERY!
G210A01A-AAT
WARNING:
Batteries can be dangerous! When work-
ing with batteries, carefully observe the
following precautions to avoid serious
injuries.
The fluid in the battery contains a strong
solution of sulfuric acid, which is poison-
ous and highly corrosive. Be careful not to
spill it on yourself or the car. If you do spill
battery fluid on yourself, immediately do
the following:
HJM5008
!
G210B04A-AATChecking the BatteryKeep the battery clean. Any evidence of
corrosion around the battery posts or ter-
minals should be removed using a solu-
tion of household baking soda and warm
water. After the battery terminals are dry,
cover them with a light coating of grease. o If battery fluid is on your skin, flush the
affected areas with water for at least 15
minutes and then seek medical assis-
tance.
o If battery fluid is in your eyes, rinse out
your eyes with water and get medical
assistance as soon as possible. While
you are being driven to get medical
assistance, continue to rinse your eyes
by using a sponge or soft cloth satu-
rated with water.
o If you swallow battery fluid, drink a large
quantity of water or milk followed by milk
of magnesia, eat a raw egg or drink
vegetable oil. Get medical assistance
as soon as possible.
While batteries are being charged (either
by a battery charger or by the vehicle's
generator), they produce explosive gases.
Always observe these warnings to prevent
injuries from occurring:
o Charge batteries only in a well venti-
lated area.
o Do not permit flames, sparks or smok-
ing in the area.
o Keep children away from the area.
PROPOSITION 65 WARNING:
Battery posts, terminals, and related
accessories contain lead and lead com-
pounds, chemicals known to the State of
California to cause cancer and repro-
ductive harm. Batteries also contain
other chemicals known to the State of
California to cause cancer. Wash hands
after handling.

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G220C01A-AATChecking Condenser Cooling FanThe condenser cooling fan should come
on automatically whenever the air condi-
tioning is in operation.G220B01A-AATChecking Engine Cooling FanThe engine cooling fan should come on
automatically if the engine coolant tem-
perature is high.CHECKING ELECTRIC COOLING
FANS!
G220A01A-AAT
WARNING:
The cooling fan is controlled by engine
coolant temperature and may some-
times operate even when the engine is
not running. Use extreme caution when
working near the blades of the cooling
fan, so that you are not injured by a
rotating fan blade. As the engine coolant
temperature decreases the fan will au-
tomatically shut off. This is a normal
condition.
If electrolyte gets on your skin,
thoroughly wash the contacted
area.
If you feel a pain or a burning
sensation, get medical atten-
tion immediately.
Wear eye protection when
charging or working near a bat-
tery.
Always provide ventilation
when working in an enclosed
space.
o When lifting a plastic-cased battery,
excessive pressure on the case may
cause battery acid to leak, resulting in
personal injury. Lift with a battery
carrier or with your hands on opposite
corners.
o Never attempt to charge the battery
when the battery cables are con-
nected.
o The electrical ignition system works
with high voltage.
Never touch these components with
the engine running or the ignition
switched on.
!
WARNING:
!
WARNING:Always read the following in-
structions carefully when han-
dling a battery.
Keep lighted cigarettes and all
other flames or sparks away
from the battery.
Hydrogen, which is a highly
combustible gas, is always
present in battery cells and
may explode if ignited.
Keep batteries out of the reach
of children because batteries
contain highly corrosive SUL-
FURIC ACID. Do not allow bat-
tery acid to contact your skin,
eyes, clothing or paint finish.
If any electrolyte gets into your
eyes, flush your eyes with
clean water for at least 15 min-
utes and get immediate medi-
cal attention. If possible, con-
tinue to apply water with a
sponge or cloth until medical
attention is received.

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POWER STEERING FLUID
LEVELG230A03A-AATThe power steering fluid level should be
checked regularly. To check the power
steering fluid level, be sure the engine is
"OFF", then check to make certain that the
power steering fluid level is between 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
conditions (below - 4°F). If the noise stops
during warm up, there is no abnormal
function in the system. It is due to a
power steering fluid characteristic in
extremely cold conditions.
G230A01JM
HEADLIGHT AIMING ADJUST-
MENTG290A03O-AATBefore performing aiming adjustment,
make sure of the following.
1. Keep all tires inflated to the correct
pressure.
2. Place the vehicle on level ground and
press the front bumper & rear bumper
down several times.
Place vehicle at a distance of 118 in.
(3m) from the test wall.
3. See that the vehicle is unloaded (ex-
cept for full levels of coolant, engine oil
and fuel, and spare tire, jack, and tools).
Have the driver or equivalent weight
placed in driver's seat.
4. Clean the head light lenses and turn on
the headlights (Low beam).
5. Open the hood.
G250A01A-AATFOR MORE INFORMATION ABOUT
YOUR HYUNDAIIf you desire additional information about
maintaining and servicing your Hyundai,
you may purchase a factory Shop Manual
at your Hyundai dealer's parts department.
This is the same manual used by dealer-
ship technicians and while it is highly tech-
nical it can be useful in obtaining a better
understanding of your car and how it works.G240A01A-AATPOWER STEERING HOSESIt is suggested that you check the power
steering hose connections for fluid leak-
age at those intervals specified in the ve-
hicle maintenance schedule in Section 5.
The power steering hoses should be re-
placed if there is severe surface cracking,
pulling, scuffing or worn spots. Deteriora-
tion of the hose could cause premature
failure. Recommended FluidUse PSF-3 type fluidNOTE:Do not start the engine when the power
steering oil reservoir is empty.

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G290B01JM-AATAdjustment After Headlight Assem-
bly ReplacementIf the vehicle has had front body repair and
the headlight assembly has been replaced,
the headlight aiming should be checked
using an aiming chart as shown in the
illustration. Turn on the headlight switch.
(Low Beam Position)
1. Adjust headlights so that main axis of
light is parallel to center line of the body
and is aligned with point "P" shown in
the illustration.
2. Dotted lines in the illustration show the
center of headlights.
G290B01B
L
W
H
Cut-off
line
Ground line
"P" Horizontal line
Vertical
line
30 mm
!
WARNING:
Never attempt to adjust the horizontal
alignment of your headlights. Horizontal
aiming must be adjusted by an autho-
rized Hyundai dealer to avoid incorrect
alignment that will reduce the effective-
ness of your headlights.
6. Draw a vertical line (through the center
of each headlight beam pattern) and a
horizontal line (through the center of
each headlight beam pattern) on the
aiming screen.
And then, draw a parallel line at 0.8 in.
(21 mm) under the horizontal line.
7. Adjust each cut-off line of the low beam
to the parallel line with a phillips screw-
driver - VERTICAL AIMING.
G290A01JM
Vertical
aiming
Horizontal
aiming

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SPECIFICATION:
"H";
Horizontal center line of headlights from
ground: 35.6 in.(904 mm)
"W";
Distance between each headlight cen-
ter:
53.4 in.(1,356 mm)
"L";
Distance between the headlights and
the wall that the lights are tested against:
118 in. (3,000 mm).
REPLACEMENT OF LIGHT
BULBS!
G260A02A-AATBefore attempting to replace a light bulb,
be sure the switch is turned to the "OFF"
position.
The next paragraph shows how to reach
the light bulbs so they may be changed. Be
sure to replace the burned-out bulb with
one of the same number and wattage
rating.
See page 6-34 for the wattage description.
CAUTION:
o Keep the lamps out of contact with
petroleum products, such as oil, gaso-
line, etc.
o After heavy, driving rain or washing,
headlight and taillight lenses could
appear frosty. This condition is
caused by the temperature difference
between the lamp inside and outside.
This is similar to the condensation on
your windows inside your vehicle
during the rain and doesn’t indicate a
problem with your vehicle. If the water
leaks into the lamp bulb circuitry, have
the vehicle checked by an Authorized
Hyundai Dealer.
G270A02O-AATHeadlight and Front Turn Signal Light1. Allow the bulb to cool. Wear eye protec-
tion.
2. Open the engine hood.
3. Always grasp the bulb by its plastic
base, avoid touching the glass.
4. Using a socket wrench of the correct
size, remove the headlight assembly
mounting bolts.
HJM5012

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HJM5016
HJM5017
6. Turn the plastic cover counterclockwise
and remove it.7. Disconnect the connector from the bulb
base in the back of the headlight.
HJM5013
5. Disconnect the power cord from the
bulb base in the back of the headlight.

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8. Push the bulb spring to remove the
headlight bulb.
9. Remove the protective cap from the
replacement bulb and install the new
bulb by matching the plastic base with
the headlight hole. Reattach the bulb
spring and reconnect the connector.
10. Use the protective cap and carton to
promptly dispose of the old bulb.
11. Check for proper headlight aim.
12. To replace the front turn signal light
bulb, remove from the bulb holder and
install the new bulb. Do not touch the
glass of the new bulb.
HJM5018G270B01JM-AAT
Rear Combination Light
!
WARNING:
This halogen bulb contains gas under
pressure and if impacted could shatter,
resulting in flying fragments. Always
wear eye protection when servicing the
bulb. Protect the bulb against abrasions
or scratches and against liquids when
lighted. Turn the bulb on only when in-
stalling in a headlight. Replace the head-
light if damaged or cracked. Keep the
bulb out of the reach of children and
dispose of the used bulb with care.
G270A03O
HJM5020
HJM5021
1. Open the tail gate.
2. Remove the mounting screws as shown
with a phillips screwdriver.