2002 Hyundai Atos check engine

VEHICLE MAINTENANCE REQUIREMENTS 5-1
NOTE: The inspection and testing of certain elec-
tronic fuel injection/engine management and automatic transmission control systems re-quire specialised electronic equipment spe-cifically designed for Hyundai vehicles. Theuse of general purpose electrical test equip-ment may result in damage to the controlunit microprocessors. be sure these are equivalent to the quality ofthe original Hyundai parts. Your Service Pass-port provides further information about yourwarranty coverage.
DF020F1-E SERVICE HISTORYIt is important that all scheduled maintenance
services are recorded in the warranty and ser- vice passport to ensure that proof of mainte-nance is available when warranty service isrequired.
DF020A1-E MAINTENANCE AND SERVICING REQUIREMENTS To ensure the continued reliability and safety of
the vehicle, certain routine maintenance opera-tions are required at specific mileage or timeintervals.
It is the responsibility of the vehicle owner to
ensure that the maintenance schedules shownin both this Owners Manual and the Warrantyand Service Passport are adhered to.
The new vehicle warranty may be invalidated if
the routine maintenance operations are notperformed in line with the recommendationsoutlined and the safety and durability of thevehicle adversely affected.
It is recommended that all maintenance opera-
tions with the exception of the daily operatingchecks are entrusted to a Hyundai dealer toensure that the latest repair and maintenanceprocedures and specialized servicing tools areemployed. In addition, the use of genuineHyundai replacement parts will ensure that thevehicle safety and performance will not becompromised. ZF010A1-A
5. VEHICLE MAINTE-
NANCE REQUIRE- MENTS
SF020C1-B Specified Scheduled ProceduresThese are the procedures such as inspections,
adjustments and replacements that are listed in the maintenance charts starting on page 5-2.These procedures must be performed at theintervals shown in the maintenance scheduleto assure that your warranty remains in effect.Although it is strongly recommended that theybe performed by the factory-trained or distribu-tor-trained technicians at your Hyundai dealer,these procedures may be performed at anyqualified service facility.
It is suggested that genuine Hyundai service
parts be used for any required repairs or re-placements. Other parts of equivalent qualitysuch as engine oil, engine coolant, manual orauto transaxle oil, brake fluid and so on whichare not supplied by Hyundai Motor Company orits distributor may be used without affectingyour warranty coverage but you should always
5

VEHICLE MAINTENANCE REQUIREMENTS 5-3
F030C02X-EAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
DESCRIPTION
GENERAL MAINTENANCE COOLING SYSTEMENGINE COOLANT ENGINE COOLANT SPECIFIC GRAVITY MANUAL TRANSAXLE OILAUTOMATIC TRANSAXLE FLUID AND FILTER BRAKE PIPES, HOSES, AND CONNECTIONS BRAKE FLUIDCLUTCH FLUID REAR BRAKE LININGS AND CYLINDERS BRAKE PADSSUSPENSION AND STEERING SYSTEM FRONT SUSPENSION BALL JOINTS POLLEN FILTERTRANSFER CASE OIL REAR AXLE OIL CLEAN PROPELLAR SHAFT/RETIGHTEN BOLTSREAR WHEEL BEARINGS TYRE CONDITION AND PRESSURE (incl uding Spare)
LUBRICATE LOCKS AND HINGES CHECK ALL ELECTRICAL SYSTEMS ROAD TEST CHECK ALL SYSTEMS WITH HI-SCAN
60 72
I I I
R I
R R
I I II
R
II I II I II I
50 60
I I I II I I I II
RRR III I II I
40 48
I I I II
RR
I I II
R
II I II I II I
30 36
I
R I I II I I I II
R
II I II I II I
20 24
I I I II
RR
I I II
R
II I II I II I
10 12
I I I II I I I II
R
II I II I II I
MILES X 1000 MONTHSNO.
1 2 3 45 6 78 9
1011 1213 14 1516 17 1819 20 2122

VEHICLE MAINTENANCE REQUIREMENTS 5-5
F060A01A-AAT EXPLANATION OF SCHEDULED MAIN-
TENANCE ITEMS
F060M01A-AAT
o Engine oil and filterThe engine oil and filter should be changed at
the intervals specified in the maintenance sched- ule. If the car is being driven in severe condi-tions, more frequent oil and filter changes arerequired.
F060B01A-AAT
o Drive belts Inspect all drive belts for evidence of cuts,
cracks, excessive wear or oil saturation and replace if necessary. Drive belts should be checked periodically for proper tension andadjusted as necessary.
F060C01A-AAT
o Fuel filterA clogged filter can limit the speed at which the
vehicle may be driven, damage the emission system and cause hard starting. If an exces-sive amount of foreign matter accumulates in
the fuel tank, the filter may require replacementmore frequently.
After installing a new filter, run the engine for
several minutes, and check for leaks at theconnections. F060D01A-AAT
o Fuel lines, fuel hoses and connec-
tions
Check the fuel lines, fuel hoses and connec-
tions for leakage and damage. Replace anydamaged or leaking parts immediately.
F060E01A-AAT
o Timing beltInspect all parts related to the timing belt for
damage and deformation. Replace any dam- aged parts immediately.
F060G01A-AAT
o Vapour hose and fuel filler capThe vapor hose and fuel filler cap should be
inspected at those intervals specified in the maintenance schedule. Make sure that a new
vapour hose or fuel filler cap is correctly re-placed.
F060F01A-AAT
o Vacuum, crankcase
ventilation hoses
Inspect the surface of hoses for evidence of
heat and/or mechanical damage. Hard andbrittle rubber, cracking, tears, cuts, abrasions,and excessive swelling indicate deterioration.Particular attention should be paid to examine
those hose surfaces nearest to high heat sourc-
es, such as the exhaust manifold. Inspect the hose routing to assure that the
hoses do not come in contact with any heatsource, sharp edges or moving component
which might cause heat damage or mechanicalwear. Inspect all hose connections, such as
clamps and couplings, to make sure they aresecure, and that no leaks are present. Hoses
should be replaced immediately if there is any
evidence of deterioration or damage.
F060H01A-AAT
o Air cleaner filter A Genuine Hyundai air cleaner filter is recom-
mended when filter is replaced.
F060J01A-AAT
o Spark plugsMake sure to install new spark plugs of the
correct heat range.
F060N01X-GAT
o Valve clearances Incorrect valve clearance will not only result in
unsteady engine operation, but will also cause excessive noise and reduced engine perfor-mance. Inspect valve clearance and adjust asrequired while the engine is hot.
Valve-to-rocker arm clearance Intake valves ..... 0.008 in. (0.2 mm)Exhaust valves .... 0.010 in. (0.25 mm)

VEHICLE MAINTENANCE REQUIREMENTS
5-6 F070B01A-GAT
o Cooling SystemCheck the cooling system part, such as radia-
tor, coolant reservoir, hoses and connections for leakage and damage. Replace any dam-aged parts.
F070C01A-AAT
o Engine coolant The coolant should be changed at the intervals
specified in the maintenance schedule.
F070D01X-GAT
o Manual or semi-automatic transaxle
oil
Inspect the manual or semi-automatic transaxle
oil according to the maintenance schedule.
NOTE: If the oil level is low, check for possible
leaks before adding oil. Do not overfill.
F070E01X-AAT
o Automatic transaxle fluidThe fluid level should be in the “HOT” range of
the dipstick, after engine and transaxle are at
normal operating temperature. Check the Auto-matic Transaxle Fluid level with the engine
running and the transaxle in neutral, with theparking brake properly applied. Use ESSOJWS3314 when adding or changing fluid. F070F01A-AAT o Brake hoses and linesVisually check for proper installation, chafing, cracks, deterioration and any leakage. Replaceany deteriorated or damaged parts immediate-ly. F070G02A-AAT
o Brake fluid Check brake fluid level in the brake fluid reser- voir. The level should be between "MIN" and"MAX" marks on the side of the reservoir. Use only hydraulic brake fluid conforming to DOT 3 or DOT 4. F070H01A-AAT
o Rear brake drums/linings, parking
brake
Check the rear brake drums and linings for
scoring, burning, leaking fluid, broken parts,and excessive wear. Inspect the parking brake
system including the parking brake lever andcables. For detailed service procedures, referto the Shop Manual. F070J01A-AAT
o Brake pads, calipers and rotorsCheck the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage. F070K01A-AAT
o Exhaust pipe and mufflerVisually inspect the exhaust pipes, muffler and hangers for cracks, deterioration, or damage.Start the engine and listen carefully for any
exhaust gas leakage. Tighten connections orreplace parts as necessary. F070L01A-AAT
o Suspension mounting bolts Check the suspension connections for loose- ness or damage. Retighten to the specifiedtorque. F070M01A-AAT
o Steering gear box, linkage & boots/
lower 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 damage. Check
the dust boots and ball joints for deterioration,cracks, or damage. Replace any damagedparts. F070N01A-AAT
o Power steering pump, belt and hos-
es
Check the power steering pump and hoses for leakage and damage. Replace any damagedor leaking parts immediately. Inspect the powersteering belt for evidence of cuts, cracks, ex-cessive wear, oiliness and proper tension.Replace or adjust it if necessary.

DO-IT-YOURSELF MAINTENANCE
6-2 ZG020B1-E
GENERAL CHECKS Engine Compartment
The following should be checked regularly:
o Engine oil level and condition
o Transaxle fluid level and condition
o Brake reservoir fluid level
o Engine coolant level
o Windscreen washer fluid level
o Accessory drive belt condition
o Coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level
o Tyre pressure and condition (including spare)
o Battery condition ZG020C1-A
Vehicle Exterior
The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut tightness
o Exhaust system condition
o Light condition and operation
o Windscreen glass condition
o Wiper blade condition
o Paint condition and corrosion
o Fluid leaks
o Door and hood lock condition o Air filter element condition G020C02X-GAT
Vehicle Interior
The following should be checked each time
when the vehicle is driven:
o Lights operation
o Windscreen wipers operation
o Horn operation
o Defroster, heating system operation (and air conditioning, if installed)
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 transaxle operation, including clutch operation
o Automatic transaxle operation, including "Park" mechanism operation
o Seat control condition and operation
o Seat belt condition and operation
o Sunvisor operation
If you notice anything that does not operate
correctly or appear to be functioning correctly, inspect it carefully and seek assistance fromyour Hyundai dealer if service is needed. ZG030A1-A
CHECKING THE ENGINE OIL
Engine oil is essential to the performance andservice of the engine. It is suggested that youcheck the oil level at least once a week innormal use and more often if you are on a tripor driving in severe conditions. ZG030B1-E
Recommended Oil
SSA6030B°C °F -25-13 20W-40 20W-50
15W-40 15W-50
10W-30
10W-40 10W-50
5W-40
5W-30
5W-20
40104
2068
1050
032
-15 5 -10-14
SH, SG or SG/CD (API) multi-grade and fuel efficient oil is recommended. NOTE: SAE 5W-20 is not recommended for sus-tained high speed vehicle operation.

DO-IT-YOURSELF MAINTENANCE 6-3
AS60050A
FL
ZG030C1-A
To Check the Oil Level
Before checking the oil, warm up the engine to
normal operating temperature and be sure it is parked on level ground. Turn the engine off.
Wait a minute, then remove the dipstick, wipe it
off, fully reinsert the dipstick and withdraw itagain. Then note the highest level the oil hasreached on the dipstick. It should be betweenthe upper ("F") and lower ("L") range. ZG030D1-A
Adding Oil
G030D01A
If the oil level is close to or below the "L" mark,
add oil until it reaches the "F" mark. To add oil:
1. Remove the oil filler cap by turning it coun- terclockwise.
2. Add oil, then check the level again. Do not overfill.
3. Replace the cap by turning it clockwise.
The distance between the "F" and "L" marks is
equal to about 1 quart of oil. G350A01A-GAT
ENGINE OIL CONSUMPTION Function of Engine Oil
Engine oil has the primary function of lubricat-
ing and cooling the inside of the engine. Engine oil consumption
If is normal that an engine should consume
some engine oil while normal driving. The cause of oil consumption in a normal engine are asfollows;
o Engine oil is used to lubricate pistons, piston rings and cylinders.
o A thin film of oil is left on the cylinder wall when a piston moves downwards in the cylinder. High negative pressure generatedduring engine operation sucks some of theoil into the combustion chamber. This oil with some oil of the cylinder wall is burned by the high temperature combustiongases during the combustion process.
o The engine oil consumption is strongly ef- fected by the viscosity and quality of oil,engine rpm and driving condition etc. The
engine oil is more consumed under severedriving conditions such as high speeds and
frequent acceleration and deceleration thannormal driving condition.

DO-IT-YOURSELF MAINTENANCE 6-5
G040A05XNOTE: Always dispose of used engine oil in an
environmentally acceptable manner. It is suggested that it be placed in a sealed con-tainer and taken to a service station forreclamation. Do not pour the oil on theground or put it into the household trash.
WARNING: Used motor oil may cause irritation or can-
cer of the skin if left in contact with the skin for prolonged periods of time. Wash yourhands thoroughly with soap and warm wa-ter as soon as possible after handling usedoil.
8. Before installing the new oil filter on the
engine, apply clean engine oil to the surfaceof the rubber gasket.Temporarily tighten the oil filter by hand.
G040A06X
9. Using the special tool (09263-02000) andtorque wrench, tighten the oil filter to the specified torque.
Tightening torque ................... 12-16 Nm (120-160 kg.cm, 9-12 lb.ft)
G040A04X
SST (09263-02000)
Extension bar
NOTE:
o Be careful not to drop the engine oil on the rubber parts of the engine mounting insulator.
o You can purchase the SST from your Hyundai dealer.
o If you aren’t sure how to use, consult your Hyundai dealer.
10. Refill the crankcase with the recommended engine oil. Refer to the specification in chap-ter 9 for engine oil capacity.
11. Start the engine and check to be sure no oil is leaking from the drain plug or oil filter.
12. Shut off the engine and recheck the oil level. ZG040B1-E
Protect the Environment: It is illegal to pollute drains, water courses or
soil. Use authorized facilities for disposal. If indoubt, contact your Local Authority for advice.
ZG050A1-A
CHECKING AND CHANGING THE EN- GINE COOLANT
WARNING: Do not remove the radiator cap when the en-
gine is hot. When the engine is hot, the coolant is under pressure and may erupt through theopening if the cap is removed. You could beseriously burned if you do not observe thisprecaution. Do not remove the cap until theradiator is cool to the touch.

DO-IT-YOURSELF MAINTENANCE
6-6 ZG050B1-A
Recommended Coolant
G050B01A
Use a high quality ethylene-glycol coolant in a
50/50 mix with water. The coolant should be compatible with aluminum engine parts. Addi-tional corrosion inhibitors or additives shouldnot be used. The cooling system must be main-tained with the correct concentration and typeof coolant to prevent freezing and corrosion.
NEVER allow the concentration of antifreeze to
exceed the 60% level or go below the 35% levelor damage to the coolant system may result.For proper concentration when adding or re-placing the coolant, refer to the following table.
Coolant concentration
ZG050C1-A
To Check the Coolant Level
G050C01A
The coolant level can be seen on the side of the
plastic coolant reservoir. The level of the cool- ant should be between the "LOW" and "FULL"lines on the reservoir. If the level is below the"LOW" mark, add coolant to bring it up between"LOW" and "FULL". If the level is low, inspectfor coolant leaks and recheck the fluid levelfrequently. If the level drops again, visit yourHyundai dealer for an inspection and diagnosisof the reason. ZG050D2-A
To Change the Coolant
The coolant should be changed at those inter-vals specified in the vehicle maintenance sched-ule in Section 5. NOTE: Coolant can damage the finish of your car. If you spill coolant on the car, wash it offthoroughly with clear water.
1. Park the car on level ground, set the parking brake and remove the radiator cap whencool.
2. Be sure your drain receptacle is in place. Open the drain cock on the radiator. Allowall the coolant to drain from the coolingsystem, then securely close the drain cock.
3. Check Section 9 for the capacity of the cooling system in your car. Then, followingthe manufacturer’s directions on the coolantcontainer, add the appropriate quantity ofcoolant to the radiator.
Water
Antifreeze
solution
35% 40%50%60%
Ambient
temperature °F (°C)
5 (-15)
-13 (-25)-31 (-35)-49 (-45) 65%60%50%40%