2002 Hyundai Atos Owner's Manual

DO-IT-YOURSELF MAINTENANCE 6-7
G050D02XG050B01A
4. Turn the radiator cap counterclockwise with- out pressing down on it, until it stops. This relieves any pressure remaining in the cool-ing system. And remove the radiator cap bypushing down and turning counterclockwise. Now fill the radiator with clean demineral- ized or distilled water. Continue to add cleandemineralized or distilled water in small quan-tities until the fluid level stays up in theradiator neck. 5. Start the engine, top off the radiator with
water and then add engine coolant to thereservoir until the level is between "LOW"and "FULL".
6. Replace the radiator and reservoir caps and check to be sure the drain cocks are fullyclosed and not leaking.
WARNING: The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper- ate even when the engine is not running.Use extreme caution when working near theblades of the cooling fan so that you are notinjured by a rotating fan blade. As the en-gine coolant temperature decreases, the fanwill automatically shut off. This is a normalcondition. AG060B1-E
SPARK PLUG REPLACEMENT
This operation should only be performed when
the engine is cold.
1. Remove plug lead from the spark plug to be replaced, pulling the lead by the rubber cap. (Pulling the lead may damage the carbonconductor).
2. Clean around the base of the plug to be removed, and install the plug socket ensur-ing that the ceramic insulator does not be-come damaged. Turn the socket anti-clock-wise to remove the plug.
G060C01A
NOTE: Spark plugs must only be cleaned using
purpose designed equipment. Wire brush-ing may damage the centre electrode insula-tor causing mis-firing to occur.

DO-IT-YOURSELF MAINTENANCE
6-8
G070A01X
(1)
SSA6060A
0.039 ~ 0.043 in. (1.0 ~ 1.1 mm)
ZG060A2-E Recommended Spark Plugs (Unleaded) NOTE: When replacing the spark plug, always use
the genuine parts recommended. G070A01X-GAT
CHANGING THE AIR CLEANER FIL- TER
To change the filter, loosen the clamps (1) on the cover. When this is done, the cover can be
lifted off, the old filter removed and the new filterput in its place. Genuine Hyundai replacementparts are recommended. CAUTION: Operating your vehicle without a proper air filter in place can result in excessive enginewear.
G060C02A
Only the correct grade of spark plug should be used. Use of an incorrect grade mayresult in serious engine damage. Prior to installing a spark plug, the gap between the centre and outer electrodesmust be checked and adjusted as neces-sary. Adjustment is facilitated by bending the outer electrode towards or away from the centreelectrode. Under no circumstances shouldattempts be made to adjust the position ofthe centre electrode.
3. Insert the spark plug into the cylinder head and screw by and until the plug contacts theseating area. Tighten the plug with the sock-et by a further 1/2 to 3/4 of a turn only.
4. Replace the plug lead ensuring that the cap is pushed firmly into place. Confirm that thecap is correctly seated by lightly pullingupon it.G060C03A CHAMPION : RC9YC4
RC10YC4
NGK : BKR5ES-11

DO-IT-YOURSELF MAINTENANCE 6-9
AS60160A
ZG080A1-A
WINDSHIELD WIPER BLADES
The wiper blades should be carefully inspected from time to time and cleaned to remove accu-mulations of road film or other debris. To clean the wiper blades and arms, use a clean sponge or cloth with a mild soap ordetergent and water. If the wipers continue to streak or smear the glass, replace them with genuine Hyundai re-placement parts or their equivalent. NOTE:
o Do not operate the wipers on dry glass. This can result in more rapid wear of the wiper blades and may scratch the glass.
o Keep the blade rubber out of contact with petroleum products such as engineoil, gasoline etc.G090A01X-EAT
FILLING THE WASHER RESERVOIR
The washer fluid reservoir supplies fluid to the
windshield washer system.
A good quality washer fluid should be used to fill
the washer reservoir. The fluid level should be checked more frequently during bad weather orwhenever the washer system is in more fre-quent use.
The capacity of the washer reservoir is 2.19
lmp.qts (2.5 Litres).
CAUTION:
o Radiator antifreeze (engine coolant) should not be used in the washer systembecause it will damage the car’s finish.
o The washer lever should not be pulled and the washer should not be operated ifthe washer reservoir is empty. This can
damage the washer fluid pump. XG100A2-E
MANUAL TRANSAXLE LUBRICANT
G100A01X
Filler plug
Drain plug
The transaxle lubricant should be checked and/
or changed at intervals specified in the mainte- nance schedule. Recommended Lubricant
Use only HYUNDAI GENUINE PARTS MTF
75W/90 (API GL-4) in the manual transaxle.
CAUTION: The transaxle lubricant level should only be
checked when the engine is cold to preludethe possibility of personal injury by contactwith hot components.
1. To check the transaxle lubricant level, the vehicle should be placed on level ground and the level plug removed with a suitablespanner.
G090A01X-DAG

DO-IT-YOURSELF MAINTENANCE
6-10
C090B01X-DAG
G110D01A-GAT To Check the Transaxle Fluid Level
G110D02A
Park the car on level ground with the parking brake engaged. When the transaxle fluid levelis checked, the transaxle fluid should be atnormal operating temperature and the engineidling.
G110A01A-AAT
CHECKING THE TRANSAXLE FLUID (AUTOMATIC)
Transaxle fluid in the automatic transaxle should be changed at those intervals specified in thevehicle maintenance schedule in Section 5.
3. Replace the bolt, screw it in with your fin-
gers and then tighten securely with thewrench.
G110C01X-EAT
Transaxle Fluid Capacity
The fluid capacity of the automatic transaxle is4.56 lmp.qts (5.2 Litres). WARNING: The transaxle fluid level should be checked when the engine is at normal operating tem-perature. This means that the engine, radia-tor, exhaust system etc., are very hot so youshould exercise great care not to burn your-self during this procedure.
G110B01X-AAT
Recommended Fluid Your Hyundai automatic transaxle is speciallydesigned to operate with ESSO JWS3314. Damage caused by a nonspecified fluid is not covered by your new vehicle limited warranty.
ZG100B1-A
To Check the Manual Transaxle Oil Level
SSA6100B
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 it with your fingers.
2. Use your finger to feel inside the hole. The oil level should be at its bottom edge. If it isnot, check for leaks before adding oil. Torefill the transaxle or bring the oil level up,add oil slowly until it reaches the properlevel. Do not overfill.
2. If the level is correct, lubricant should begin
to drip from the plug orifice. In this case theplug should be replaced. If the level is incor-rect, lubricant should be added until it beginsto drip from the plug orifice at which time theplug should be replaced.

DO-IT-YOURSELF MAINTENANCE 6-11
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". With the engine stillidling:
1. Open the hood, being careful to keep hands, long hair and clothing clear of any movingparts.
2. Remove the transaxle dipstick, wipe it clean, reinsert the dipstick as far as it will go, thenremove it again. Now check the fluid level on
the dipstick. It should be in the "HOT" rangeon the dipstick.
Fluid level must be within this range
3. If the transaxle fluid level is low, use a funnel to add transaxle fluid through the dipsticktube until the level reaches the "HOT" range.
Do not overfill.
G110D03A
G120A01A-AAT CHECKING THE BRAKES CAUTION: Because brakes are essential to the safe oper- ation of the car, it is suggested that they bechecked and inspected by your Hyundai dealer.The brakes should be checked and inspectedfor wear at those intervals specified in thevehicle maintenance schedule in Section 5. G120B01A-AAT
Checking the Brake Fluid Level WARNING:
Use caution when handling brake fluid. It
can damage your vision if it gets into your eyes. It will also damage your vehicle’s paint
if spilled on it and not removed immediately.
G120C02A-AAT
Recommended Brake Fluid Use only hydraulic brake fluid conforming to
DOT 3 or DOT 4 specifications in your brakingsystem. Follow the instructions printed on thecontainer.
G120D01A-AAT
To Check the Fluid Level The fluid level in the brake fluid reservoir should
be checked periodically. The level should bebetween the "MIN" and "MAX" marks on theside of the reservoir. If the level is at or below
the "MIN" mark, carefully add fluid to bring it upto "MAX". Do not overfill.
WARNING: The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper- ate even when the engine is not running.
Use extreme caution when working near theblades of the cooling fan, so that you are notinjured by a rotating fan blade. As the en-
gine coolant temperature decreases, the fanwill automatically shut off. This is a normalcondition. NOTE:
Only lint free cloth should be used for wip-
ing the dipstick. The presence of lint within the transaxle may cause problems with thenormal function of the transaxle.

DO-IT-YOURSELF MAINTENANCE
6-12 the instruments to check it with a force of 22 lb. (98N), the deflection should be approx. 0.197 ~0.217 inches (5 ~ 5.5 mm). If the belt is tooloose, have it adjusted by your Hyundai dealer. ZG140C1-E
Checking the Refrigerant
1. Start the engine and let it run at fast idle for several minutes with the air conditioner set at one of its colder settings.
2. Open the hood and check two hoses by touching with your fingers. One line is theevaporator inlet, the other is the outlet. Ifthere is a temperature difference betweenthe two hoses, the refrigerant is low and thesystem should be recharged by your Hyundaidealer.
CAUTION:Running the air conditioning system for ex-tended periods of time with a low refrigerantlevel may damage the compressor. ZG140D1-A
Lubrication To lubricate the compressor and the seals in the system, the air conditioner should be run forat least 10 minutes each week. This is particu-larly important during cool weather when the airconditioning system is not otherwise in use.
G140A01A-AAT
AIR CONDITIONING CARE Keeping the Condenser Clean
The air conditioning condenser (and engine
radiator) should be checked periodically for accumulation of dirt, dead insects, leaves, etc.
These can interfere with maximum cooling effi-
ciency. When removing such accumulations,brush or hose them away carefully to avoidbending the cooling fans.
G140D01X-EAT
Checking the Compressor Drive Belt
G140D01X
A/C pulley
0.197 ~ 0.217 in. (5 ~ 5.5 mm)
Crank pulley
When the air conditioning is being used regular-
ly, the compressor drive belt tension should be checked at least once a month.
To check the drive belt tension, press down on
the belt halfway between the engine crankshaftand compressor pulleys. Pressing with yourfinger, you should not be able to deflect this beltanymore than 0.197 ~ 0.217 inches. If you have
G120E01X-DAG
G120E02A-AAT
Adding Brake Fluid WARNING:
Handle brake fluid carefully. It can damage
your vision if it gets into your eyes. Use only DOT 3 or DOT 4 specification fluid from a
sealed container. Do not allow the fluid canor reservoir to remain open any longer than
required. This will avoid entry of dirt andmoisture which can damage the brake sys-tem and cause improper operation.
To add brake fluid, first wipe away any dirt then
unscrew the fluid reservoir cap. Slowly pour therecommended fluid into the reservoir. Do notoverfill. Carefully replace the cap on the reser-voir and tighten.

DO-IT-YOURSELF MAINTENANCE 6-13
ZG150A1-A
CHECKING STEERING WHEEL FREEPLAY
AS60260A
1.18 in. (30 mm)
To check the steering wheel freeplay, stop the
car with the wheels pointed straight ahead and gently move the steering wheel back and forth.Use very light finger pressure and be sensitiveto changes in resistance that mark the limits ofthe freeplay. If the freeplay is greater thanspecified, have it inspected by your Hyundaidealer and adjusted or repaired if necessary. ZG160A1-A CHECKING CLUTCH PEDAL FREEPLAY
SSA6160A
0.24~0.51 in. (6 ~ 13 mm)
With the engine off, press lightly on the clutch pedal until you feel a change in resistance. Thisis the clutch pedal freeplay. The freeplay shouldbe within the limits specified in the illustrationbelow. If it is not, have it inspected by yourHyundai dealer and adjusted or repaired if nec-essary.
SSA6170A
0.12 ~ 0.31 in. (3 ~ 8 mm)
ZG170A1-A
CHECKING BRAKE PEDAL FREEPLAY
With 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 inresistance. This is the brake pedal freeplay.
The freeplay should be within the limits speci-
fied in the illustration below. If it is not, have itinspected by your Hyundai dealer and adjustedor repaired if necessary.

DO-IT-YOURSELF MAINTENANCE
6-14 AG200A1-A
CHECKING AND REPLACING FUSES Replacing a Fusible Link
G200A01A
Bad
Good
A fusible link will melt if the electrical circuits from the battery are ever overloaded, thus pre- venting damage to the entire wiring harness.(This could be caused by a short in the systemdrawing too much current.) 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 foreasy inspection. CAUTION: When replacing a fusible link, never use anything but a new fusible link with thesame or lower amperage rating. Never use apiece of wire or a higher-rated fusible link.This could result in serious damage andcreate a fire hazard.
ZG190A1-A
CHECKING DRIVE BELTS
G190A01A
Water pump pulley
Generator 0.37 ~ 0.43 in. (9.5~11.0 mm) Crankshaft pulley
Drive belts should be checked periodically for proper tension and adjusted if necessary. At thesame time, belts should be examined for cracks,wear, fraying or other evidence of deteriorationand replaced if necessary. Belt routing should also be checked to be sure there is no interference between the belts andother parts of the engine. After a belt is re-placed, the new belt should be adjusted againafter two or three weeks to eliminate slackresulting from initial stretching after use.
ZG180A1-A
CHECKING BRAKE PEDAL CLEARANCE
SSA6180A
1.42 in. (36 mm)
You need a helper to check the brake pedal
clearance. With the engine running, have your helper press down on the brake pedal severaltimes and then hold it down with a force of about110 lbs (50 kg, 490 N). The brake pedal clear-ance is the distance from the top surface of thebrake pedal to the asphalt sheeting under thefloor mat.
If the brake pedal clearance is not within the
limits specified in the illustration, have it in-spected by your Hyundai dealer and adjustedor repaired if necessary.