2003 Hyundai Getz engine

6- 22 DO-IT-YOURSELF MAINTENANCE
G180A01A-GAT CHECKING BRAKE PEDAL CLEARANCE
G180A01L
1.78 in. (45.1 mm)
You need a helper to check the brake pedal clearance. With the engine run- ning, have your helper press down on the brake pedal several times and thenhold it down with a force of about 490 N (50 Kg, 110 lbs). The brake pedal clearance is the distance from the topsurface of the brake pedal to the as- phalt sheeting under the floor mat. If the brake pedal clearance is notwithin the limits specified in the illustra- tion, have it inspected by your Hyundai dealer and adjusted or repaired if nec-essary.SG170A1-E BRAKE PEDAL FREEPLAY
HXGS508
0.12 ~ 0.31 in. (3 ~ 8 mm)
The brake pedal freeplay should be checked with the engine turned off. Thepedal to floor clearance should be checked with the engine running and a load of 490 N applied to the pedal. Ifeither value is incorrect, the necessary adjustment should be performed by a Hyundai dealer. Pedal to floor clear-ance: 1.97 in. (50 mm)SG160A1-E CLUTCH PEDAL FREEPLAY
G160A01E
0.24 ~ 0.51 in. (6 ~ 13 mm)
The clutch pedal freeplay should be checked against the specified value. If the freeplay is not correct, the clutch should be adjusted by a Hyundai dealer.

DO-IT-YOURSELF MAINTENANCE 6- 23
The various engine drive belts must be checked for condition, tension and free- dom from damage and excessive wear.The tension of a new belt must be checked after thirty minutes running following fitment of the new belt to allowfor the initial belt stretch. G190B01TB-GAT CHECKING DRIVE BELTS (Diesel)
A/C comp.
Auto tensioner Pulley
G190B01TB
AlternatorPower steering pump
At the scheduled maintenance inspec- tion, belts should be examined forcracks, wear, fraying or other evidence of deterioration and replaced if neces- sary.Belt routing should also be checked to be sure there is no interference be- tween the belts and other parts of theengine.
Crankshaft Pulley
SG190A1-E DRIVE BELTS (Gasoline)
1.1L
1.3L/1.6L Alternator
0.37 ~ 0.43 in. (9.5 ~11.0 mm)
Water Pump Pulley
Alternator Pulley
0.2~0.24 in.(5.1~6 mm)
HTB186
Crankshaft pulley
HTB220
Water Pump Pulley

DO-IT-YOURSELF MAINTENANCE 6- 25
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o If battery electrolyte is spilled onto
skin or into eyes, the effected area must be flushed with copiousamounts of water and medical assis- tance sought.
o If battery electrolyte is ingested, copious amounts of water or milkfollowed by an ant-acid (raw egg or milk of magnesia) must be drunk.Vomiting should not be induced and medical assistance must be sought.
o Batteries must only be charged in well venti-lated areas from whichnaked lights or sources of sparks are excluded.
o Ensure that children, pets or other unauthorized persons are kept awayfrom batteries.
o Do not allow anything to bridge the positive (+) and negative (-) termi-nals of the battery.
o Never invert the battery. The battery fitted during production is of the "Maintenance Free" type.
SG210A1-E BATTERY MAINTENANCE
WARNING:
Motor vehicle batteries contain sulphuric acid which is corrosive and poisonous. Hydrogen gas isemitted from the battery which is explosive when combined with oxy- gen. The following precautions mustbe strictly observed to avoid per- sonal injury or damage to the ve- hicle.
HTB165 SG220A1-E ELECTRIC COOLING FANS
WARNING:
The cooling fan is controlled by en- gine 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 auto- matically shut off. This is a normal condition. The engine cooling fan should operate before the temperature gauge reachesthe upper portion of the scale and the condenser fan should operate when- ever the air conditioning is in use.

6- 26 DO-IT-YOURSELF MAINTENANCE
HTB287
SG230B1-E POWER STEERING HOSES Power steering hoses should be checked for damage, deterioration andleakage at each service.
steering fluid level is between the "MAX" and "MIN" level markings on the fluid reservoir. NOTE: Grinding noise from power steering pump may be heard immediatelyafter the engine is started in extremely
cold condition (below -4°F). If the noise stops during warm up, there isno abnormal function in the system. This is due to a power steering fluid characteristic in extremely cold con-ditions. FLUID RECOMMENDATION Only automatic transmission fluid meet- ing the specification of Dexron 2 shouldbe used in the power steering system.
G300A01TB-GAT REMOVAL OF WATER FROM THE FUEL FILTER(DIESEL ENGINE) If the fuel filter warning lamp illuminates during driving, it indicates that waterhas accumulated in the fuel filter. If this occurs, remove the water as described.
SG230A2-E POWER STEERING FLUID LEVEL The power steering fluid level should be checked daily.To check the power steering fluid level, be sure the ignition is "OFF", then check to make certain that the power
HTB163

DO-IT-YOURSELF MAINTENANCE 6- 27
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5. Open the bonnet.
6. Draw the vertical line (through the
center of each headlight beam pat-tern) and the horizontal line (throughthe center of each headlight beam pattern) on the aiming screen. And then, draw the horizontal paral- lel line at 1.18 in. (30 mm ) under the horizontal line.
7. Adjust each cut-off line of the low beam to the parallel line with a phillipsscrewdriver - VERTICAL AIMING.
8. Adjust each cut-off line of the low
beam to each vertical line with aphillips screwdriver - HORIZONTAL AIMING. HTB269
Horizontal Aiming
Vertical Aiming
G290A01FC-EAT HEADLIGHT AIMING ADJUST- MENT Before 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 and rear bumper down several times. Place the vehicle at a distance of 118 in. (3,000 mm) from the test wall.
3. See that the vehicle is unloaded (except for full levels of coolant,engine oil and fuel, and spare tire,jack, and tools).
4. Clean the head lights lens and turn
on the headlight (low beam). WARNING:
Be sure to carefully wipe away anywater drained out in this manner, because the fuel mixed in the water might be ignited and result in a fire.
1. Remove the engine cover.
2. Disconnect the air intake hose from air cleaner cover.
3. Loosen the drain plug at the bottom
of the fuel filter.
4. Tighten the drain plug when water no longer comes out.
5. Check to be sure that the warning lamp illuminates when the ignition key is turned to "ON", and that it goes off when the engine is started.If in doubt, consult your nearest au- thorized HYUNDAI dealer.
G300B01FC

6- 34 DO-IT-YOURSELF MAINTENANCE
G200C01TB-GAT FUSE PANEL DESCRIPTION Engine Compartment
HTB261-EPROTECTED COMPONENTS
Ignition Switch
Ignition Switch, Start Relay
Fuel pump, Alternator, ECM
Auto Fuel Cut Switch
Radiator Fan
Headlight, Defogger RelayABSECMA/CON, Fuel PumpInjectorA/Conditioner
HornABSABS
Blower, Blower Motor
Power Window
Electronic power steering AlternatorSpare Fuse Spare FuseSpare Fuse
FUSE RATING
30A30A30A20A30A50A10A10A10A15A10A10A20A40A30A30A50A 15A 10A10A
DESCRIPTION
IGN 2IGN 1ECU
F/PUMP RAD
BATT ABS
ECU
SNSR INJ
A/CON HORN ABS1ABS2 BLW
P/WDW EPS
BATT( ) SPARE
SPARE
SPARE
NOTE:
Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time of printing. When you inspect the fuse box on your vehicle, refer to the fuse box label.
1.1L 1.3/1.6L 100A120A

7- 2 EMISSION CONTROL SYSTEMS
SH010A1-E EMISSION CONTROL SYSTEMS (Not all models) Depending upon the market for which the vehicle is destined, the emissioncontrol system will comprise one or more of the following emission con- trol devices. 1) Crankcase emission control sys-
tem
2) Evaporative emission control sys-
tem
z3) Exhaust emission control systemIn order that the proper functioning of the emission control systems may be ensured, it is recommended that the vehicle is inspected and maintainedby an authorized Hyundai dealer in accordance with the maintenance schedule in this manual. SH010B1-E
1. CRANKCASE EMISSION
CONTROLSYSTEM
The positive crankcase ventilation
system is employed to prevent airpollution caused by blow-by gasesbeing emitted from the crankcase by introducing fresh air to the crankcase through the air cleaner where thismixes with blow-by gases and then passes through the PCV valve into the intake manifold from where it sub-sequently enters the combustion chamber and is burned.
SH010C1-E
2. EVAPORATIVE EMISSION
CONTROL SYSTEM
The Evaporative Emission Control
System is designed to prevent fuel vapours from escaping into the atmo- sphere through the fuel tank ventila- tion system.
Whilst the engine is not running, fuel
vapours generated inside the fuel tankare absorbed and stored in a char-coal canister. When the engine is started, the vapours stored in the canister are drawn into the induction SH010D1-E
3. EXHAUST EMISSION CON
TROL SYSTEM
The exhaust emission control system
is a highly effective system whichcontrols exhaust emission while main- taining good vehicle performance.
system through the purge control so-lenoid valve and are subsequently burned.
The purge control solenoid valve is
controlled by the ECU; when the en-gine coolant temperature is low or the engine is idling, the purge control valve is closed and fuel vapours re-main stored in the canister. Under normal running conditions when the engine is warm, the valve opens andthe vapours are drawn into the inlet tract and subsequently burned in the combustion chamber.

EMISSION CONTROL SYSTEMS 7- 3
H020A01TB-EAT
CATALYTIC CONVERTOR OP- ERATION PRECAUTIONS ; For a Petrol engine
Hyundai Getz models are fitted with
catalytic convertors which require special operating considerations. Thecatalytic convertor serves to oxidize certain noxious elements of the ex- haust gases leaving the engine toreduce the level of pollutants emitted from the vehicle and, provided that care is exercised to prevent damage,the catalyst will operate efficiently for the life of the vehicle.
It is of the utmost importance that the
following information is read and un-derstood by the vehicle operator in
HTB178Catalytic Converter order to prevent operational problems arising from damage to the catalyst.
Damage to the catalyst will result if
contamination occurs through the use of leaded fuel. Whilst the vehicle isfitted with a reduced diameter filler neck to prevent charging of the fuel tank with a leaded fuel pump nozzle,it is possible that the use of funnels or jerry cans will permit leaded fuel to be introduced into the fuel tank.
The catalyst is intolerant of unburnt
fuel and therefore if an engine misfirecondition exists, damage to the cata-lyst will occur. It is imperative that if a misfire condition develops, the ve- hicle is immediately presented to aHyundai dealer for rectification. Simi- larly, the practice of certain ignition system diagnosis procedures whichinvolve inducing a misfire (cylinder power balance tests for example) may result in catalyst damage.
For these reasons, it is advisable that
the exhaust gas emission be testedat each routine service with a gas analyzer having a Hydrocarbon mea- suring facility to ensure continuedreliability of the catalyst. Push or tow starting of the vehicle is to be avoided since unburnt fuel may be enter the catalyst and result indamage. (Note, it is impossible to push or tow start a Hyundai model equipped with fuel injection since thefuel pump safety interlock will prevent the pump from operating under these conditions).Operation of the catalyst involvesextremely high temperatures beingattained within the catalytic conver- tor, and although the convertor is fitted with heat shields, it is importantthat the vehicle is not parked over combustible or volatile material which may result in fire. If the above precautions are not ad- hered to and the catalyst becomes inoperative, the resultant increase incore temperature will result in a "melt down" where the catalyst core will melt and subsequently may block theexhaust system.Due to the fragile nature of the cata-lyst element, it is important that dam- age does not occur when the vehicle is raised by means of a garage jack.Care must also be exercised to avoid driving over road hazards or debris which may cause damage to the cata-lyst element.