2003 Hyundai H-1 (Grand Starex) manual transmission

IN CASE OF EMERGENCY
IN CASE OF EMERGENCY IN CASE OF EMERGENCY
IN CASE OF EMERGENCY
IN CASE OF EMERGENCY
4-12 normal for cold water to be draining from it when you stop).
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
While the engine is running, keep hair, hands,
While the engine is running, keep hair, hands, While the engine is running, keep hair, hands,
While the engine is running, keep hair, hands,
While the engine is running, keep hair, hands,
long hair and
long hair and long hair and
long hair and
long hair and clothing away from moving
clothing away from moving clothing away from moving
clothing away from moving
clothing away from moving
parts such as the fan and drive belts to
parts such as the fan and drive belts to parts such as the fan and drive belts to
parts such as the fan and drive belts to
parts such as the fan and drive belts to
prevent
prevent prevent
prevent
prevent injury.
injury. injury.
injury.
injury.
5. If the water pump drive belt is broken or engine coolant is leaking out, stop the en-gine immediately and call the nearestHyundai dealer for assistance.
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
Do not remove the radiator cap when the
Do not remove the radiator cap when the Do not remove the radiator cap when the
Do not remove the radiator cap when the
Do not remove the radiator cap when the
engine is hot. This
engine is hot. This engine is hot. This
engine is hot. This
engine is hot. This can allow coolant to be
can allow coolant to be can allow coolant to be
can allow coolant to be
can allow coolant to be
blown out of the opening and cause serious
blown out of the opening and cause serious blown out of the opening and cause serious
blown out of the opening and cause serious
blown out of the opening and cause serious
burns.
burns. burns.
burns.
burns.
GS40280A
6. If you cannot find the cause of the overheat-
ing, wait until the engine temperature has returned to normal. Then, if engine coolant
has been lost, carefully remove the radiator
cap and add engine coolant to bring the fluidlevel in the reservoir up to the halfway mark.
7. Proceed with caution, keeping alert for fur- ther signs of overheating. If overheating hap-pens again, call a Hyundai dealer for assis-tance.
CAUTION:
CAUTION: CAUTION:
CAUTION:
CAUTION:
Serious loss of engine coolant indicates
Serious loss of engine coolant indicates Serious loss of engine coolant indicates
Serious loss of engine coolant indicates
Serious loss of engine coolant indicates
there is a leak in
there is a leak in there is a leak in
there is a leak in
there is a leak in the cooling system and this
the cooling system and this the cooling system and this
the cooling system and this
the cooling system and this
should be checked as soon as possible by a
should be checked as soon as possible by a should be checked as soon as possible by a
should be checked as soon as possible by a
should be checked as soon as possible by a
Hyundai
Hyundai Hyundai
Hyundai
Hyundai dealer.
dealer. dealer.
dealer.
dealer.
GS40270A
3. If engine coolant is running out under the car
or steam is coming out from the hood, stop the engine. Do not open the hood until theengine coolant has stopped running or thesteaming has stopped. If there is no visibleloss of engine coolant and no steam, leavethe engine running and check to be sure theengine cooling fan is operating. If the fan isnot running, turn the engine off.
4. Check to see if the water pump drive belt is missing. If it is not missing, check to seethat it is tight. If the drive belt seems to besatisfactory, check for engine coolant leak-ing from the radiator, hoses or under the car.(If the air conditioning had been in use, it is
1. Pull off the road and stop as soon as it is
safe to do so.
2. Place the gear selector lever in "P" (auto- matic), or neutral (manual transmission) andset the parking brake. If the air conditioning
is on, turn it off.

6-3
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
DESCRIPTION
GENERAL MAINTENANCE ENGINE COOLANT *1 MANUAL TRANSMISSION OILAUTOMATIC TRANSMISSION OILTRANSFER CASE OIL *2REAR AXLE OILCLUTCH / BRAKE PEDAL FREE PLAY CLUTCH / BRAKE OIL RESERVOIR BRAKE HYDRAULIC FLUIDFRONT BRAKE PADSFRONT BRAKE CALIPERS / CYLINDERS / DISCREAR BRAKE DRUMS / LININGS / CYLINDERSHANDBRAKETIRE CONDITION / PRESSURE EXHAUST SYSTEM / MOUNTING STEERING JOINT / RACK / BOX OIL LEAKSSUSPENSION JOINT / SEALSFRONT WHEEL BEARINGENGINE COOLANT HOSESBRAKE PIPE CORROSION SEATBELTS / MOUNTINGS HEAD LAMPSAIR FILTER (For Evaporator and Blower unit) *3
NO.
123456 7 89
10111213 14 1516171819 20 2122
G030A04P-GAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
70 56
I I I I I I III I I 80 64
I I
R II I IIII I I IIII I90 72
I I I III I I I I I II
20 16
I I I II I IIIII I IIII I 30 24
I I I III I III I II 40 32
I I
R II I III I I IIIII I 50 40
I I I I I I III I I 60 48
I I I IIIII I I I I IIIIIII
See below
KILOMETERS X 1000 MONTHS
54
R 10
8
I I I I I I III I I
See below
*1. For every 24 months or 40,000 km, whichever occurs first : "R"
*2. For every 24 months or 48,000 km, whichever occurs first : "R"
*3. For every 12 months or 20,000 km, whichever occurs first : "R" See below

6-7
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
DESCRIPTION
GENERAL MAINTENANCE ENGINE COOLANT *1 MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL TRANSFER CASE OIL *2 REAR AXLE OIL CLUTCH/BRAKE PEDAL FREEPLAY CLUTCH/BRAKE OIL RESERVOIR BRAKE HYDRAULIC FLUID FRONT BRAKE PAD FRONT BRAKE CALIPERS/CYLINDERS/DISC REAR BRAKE DRUMS/LININGS/CYLINDERS HAND BRAKE TIRE CONDITION/PRESSURE EXHAUST SYSTEM/MOUNTING STEERING JOINT/RACK/BOX/OIL LEAKS SUSPENSION JOINT/SEALS FRONT WHEEL BEARING ENGINE COOLANT HOSES BRAKE PIPE CORROSION
AIR FILTER (F o r Evapoerator and Blower unit) *3
NO.
12 3 4 5 6 7 8 9
1011 12 13 14 15 16 17 18 19 20KILOMETERS X 1000 MONTH90 72
I
R R I I I I I I I I I I I I I I
G060A04P-GAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY15 12
II I I I I I I I 30 24
II I I I I I I I I I I I I I I I 4536
II
R II I I I I 60 48
II I I I I I I I I I I I I I I I 7560
II I I I I I I I7.5 6
R
See below See below
*1. For every 24 months or 45,000 km, whichever occurs first : "R" *2. For every 24 months or 48,000 km, whichever occurs first : "R"*3. For every 12 months or 20,000 km, whichever occurs first : "R"
See below

PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
6-8 GASOLINE DIESEL
E VERY
Except E.C EV ERY 3,000 KM
5,000 KM EV ERY 4,000 KM (Except 2.5 CRDi)
or 3 MONTHS EV ERY 7,500 KM or 6 MONTHS (2.5 CRDi only)
MORE FREQUENTLY
MORE FREQUENTLY
EV ERY 60,000 K M or 4 8 MONTHS (Except 2.5 CRDi)
MORE FREQUENTLY
MORE FREQUENTLY
EV ERY 10,000 K M o r 6 MONTHS
MORE FREQUENTLY
EV ERY 100,000 K M
EV ERY 40,000 K M
EV ERY 45 ,000 K M
R R R R
I II
RR R
G070A06P-GAT
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
MAINTENANCE UNDER SEVERE USAGE CONDITIONS MAINTENANCE UNDER SEVERE USAGE CONDITIONS
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate
maintenance intervals.
R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGS TIMING BELT BRAKE PADS, CALIPERS, ROTORSREAR BRAKE DRUMS/LININGSSTEERING GEAR BOX, LINKAGE & BOOTS
AIR FILTER (F o r Evaporator and Blower unit)
MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL A, B, C, F, H C, E B, H D, E, F, G C, D, G, HC, D, G, HC, D, E, FC,EA, C, D, E, F, G, H, I, J A, C, E, F, G, H, I
SEVERE DRIVING CONDITIONS
SEVERE DRIVING CONDITIONS SEVERE DRIVING CONDITIONS
SEVERE DRIVING CONDITIONS
SEVERE DRIVING CONDITIONS
A - Repeated short distance driving
B - Extensive idling
C - Driving in dusty conditions
D - Driving in areas using salt or other corrosive materials or in very cold weatherE - Driving in sandy areas
F - More than 50% driving in heavy city traffic during hot above 32°C (90°F)
G - Driving in mountainous areas
H - Towing a trailer or police car, taxi, or commercial type operation
I - Driving for patrol car, taxi, commercial car or vehicle towing
J - Driving over 170 km/h
For E.C
MAINTENANCE ITEM MAINTENANCE
OPERATION MAINTENANCE
INTERVALS DRIVING
CONDITION
Except E.C For E.C

PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
6-10 G080N01P-GAT
oo
oo
o Brake hoses and lines
Brake hoses and lines Brake hoses and lines
Brake hoses and lines
Brake hoses and lines
Visually check for proper installation, chafing, cracks, deterioration and any leakage. Replaceany deteriorated or damaged parts immedi-ately. G080O01P-GAT
oo
oo
o Brake fluid
Brake fluid Brake fluid
Brake fluid
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. Useonly hydraulic brake fluid conforming SAEJ1703. G080P01P-GAT
oo
oo
o Rear brake drums and linings
Rear brake drums and linings Rear brake drums and linings
Rear brake drums and linings
Rear brake drums and linings
Check for scoring, burning, leaking fluid, bro- ken parts, and excessive wear. G080Q01P-GAT
oo
oo
o Brake pads, calipers and rotors
Brake pads, calipers and rotors Brake pads, calipers and rotors
Brake pads, calipers and rotors
Brake pads, calipers and rotors
Check the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage. G080R01P-GAT
oo
oo
o
Parking brake
Parking brake Parking brake
Parking brake
Parking brake
Inspect the parking brake system such as parking brake lever, cables, and so on. Fordetailed service procedures, refer to the ShopManual. G080S01P-GAT
oo
oo
o
Exhaust pipe connections,
Exhaust pipe connections, Exhaust pipe connections,
Exhaust pipe connections,
Exhaust pipe connections,
muffler and suspension bolts
muffler and suspension bolts muffler and suspension bolts
muffler and suspension bolts
muffler and suspension bolts
Check the exhaust pipe, muffler, and suspen-sion connections for looseness or damage. G080T01P-GAT
oo
oo
o
Steering gear box, linkage and boots
Steering gear box, linkage and boots Steering gear box, linkage and boots
Steering gear box, linkage and boots
Steering gear box, linkage and boots
With the vehicle stopped and engine off, check for excessive free-play in the steering wheel.Check the linkage for bends or damage. Checkthe dust boots and ball joints for deterioration,cracks, or damage. Replace any damaged parts. G080U01P-GAT
oo
oo
o Wheel bearing grease
Wheel bearing grease Wheel bearing grease
Wheel bearing grease
Wheel bearing grease
Check the wheel bearings and grease accord- ing to the maintenance schedule. For inspec-tion procedures, see Shop Manual.
G080J01P-GAT
oo
oo
o Engine coolant
Engine coolant Engine coolant
Engine coolant
Engine coolant
The coolant should be changed at those inter-
vals specified in the Vehicle Maintenance Re-quirements Section.
G080K01P-GAT oo
oo
o
Timing belt
Timing belt Timing belt
Timing belt
Timing belt
Inspect all parts related with the timing belt for
damage and deformation. Replace any dam-aged parts.
G080L01P-GAT oo
oo
o Manual transmission oil
Manual transmission oil Manual transmission oil
Manual transmission oil
Manual transmission oil
Check manual transaxle oil according to the
maintenance schedule.
NOTE:
NOTE: NOTE:
NOTE:
NOTE:
If the oil level is low, check for possible
If the oil level is low, check for possible If the oil level is low, check for possible
If the oil level is low, check for possible
If the oil level is low, check for possible leaks before adding oil. Do not overfill.
leaks before adding oil. Do not overfill. leaks before adding oil. Do not overfill.
leaks before adding oil. Do not overfill.
leaks before adding oil. Do not overfill.
G080M02P-GAT oo
oo
o
Automatic transmission fluid
Automatic transmission fluid Automatic transmission fluid
Automatic transmission fluid
Automatic transmission fluid
The 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 enginerunning and the transaxle in neutral, with theparking brake properly applied. Use GENUINEHYUNDAI ATF AUTOMATIC TRANSMISSIONFLUID, DIAMOND ATF DEXRON II or DIA-
MOND ATF SP I when adding or changing
fluid.

CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
8-6 I040A01P-GAT
Vehicle Interior
Vehicle Interior Vehicle Interior
Vehicle Interior
Vehicle Interior
The following should be checked each time when the vehicle is driven:
o Light operation
o Windshield wiper operation
o Horn operation
o Defroster, heater operation (and air condi- tioning, if equipped)
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 transmission operation, including clutch operation
o Automatic transmission 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. Adequate care of your vehicle at regular inter- vals serves to preserve the value and appear-ance as long as possible. Some maintenance items can be carried out bythe owner (Consumer Information), while othershould be done only by an authorized dealer(Periodic Inspection and Maintenance). Thissection describes only those items which canbe carried out by the owner. In the event amalfunction or other problem is discovered,have it corrected by an authorized HYUNDAIdealer. This section contains information oninspection maintenance procedures that youcan do yourself, if you so desire. Follow theinstructions and cautions for each of the vari-ous procedures. When checking or servicing the inside of the engine compartment, be sure the engine isstopped and has had a chance to cool down. Ifit is necessary to do work in the engine com-partment with the engine running, be especiallycareful that your clothing, hair, etc., becomesnot caught by the fan, V-belts, or other movingparts. I050A01P-GAT
Inspection items
Inspection items Inspection items
Inspection items
Inspection items
( 1 ) Engine oil
( 2 ) Engine coolant
(3) Battery
( 4 ) Brake fluid
( 5 ) Clutch fluid (hydraulic clutch only)
( 6 ) Washer fluid
( 7 ) Wheel condition (including spare wheel)
(8) Tire inflation pressure (including spare
wheel)
I020A02P-GAT
GENERAL CHECKS
GENERAL CHECKS GENERAL CHECKS
GENERAL CHECKS
GENERAL CHECKS
Engine Compartment
Engine Compartment Engine Compartment
Engine Compartment
Engine Compartment The following should be checked regularly:
o Engine oil level and condition
o Transmission fluid level and condition
o Brake fluid level
o Clutch fluid level
o Engine coolant level
o Windshield washer fluid level
o Accessory drive belt condition
o Coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level and condition
o Tire pressure and condition (including spare)
o Battery condition I030A02P-GAT
Vehicle Exterior
Vehicle Exterior Vehicle Exterior
Vehicle Exterior
Vehicle Exterior The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut tightness
o Air cleaner filter condition
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and corrosion
o Fluid leaks
o Door and hood lock condition

VEHICLE SPECIFICATIONS
VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS
VEHICLE SPECIFICATIONS
VEHICLE SPECIFICATIONS
9-4 Quantity (liter)
Minibus, Van : 1.3 0.8
Minibus : 13, Van : 10, Truck : 7.2 As required As required
Minibus, Van : 2.6, Truck : 1.7
As required Diesel
2.6 N/A(long Van) : 8.5 2.6 N/A : 72.5 4D56 T/C : 8.52.5 4D56 TCI(3Van, 11/12Minibuss) : 8.52.5 4D56 TCI EURO III(3Van, 11/12Minibuss) : 7.53
2.5 4D56 TCI EURO III(6Van, 7/9Minibuss) : 7.53
2.5 4D56 TCI(4WD) : 9.832.5 CRDi TCI(2WD) : 8.32.5 CRDi TCI(4WD) : 11.7
Recommended in field
HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4) DIAMOND ATF DEXRON II, DIAMOND ATF SP I
DIAMOND ATF SP II
PSF-3 HIGH QUALITY ETHYLENE GLYCOL BASE FOR ALUMINUM RADIATORSAE J 1703 EQUIVALENTSAE J310a, MULTI-PURPOSE GREASE NLGI-2 OREQUIVALENT.
API GL-4 (MS517-15) : SAE 90, 140
API GL-5 (MS517-15) : SAE 80
Items
MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL TRANSFER CASE OIL POWER STEERING OIL COOLANT CLUTCH & BRAKE FLUIDFRONT, REAR WHEEL BEARING REAR AXLE STEERING GEAR BOX
Gasoline 2.0 Diesel
2.6 N/A : 2.0 2.5 4D56 T/C or TCI : 2.42.5 CRDi TCI : 3.2
Gasoline
7.53
J060A05P-GATLUBRCATION CHART
LUBRCATION CHART LUBRCATION CHART
LUBRCATION CHART
LUBRCATION CHART

10-3
INDEX
INDEX INDEX
INDEX
INDEX
J JACK HANDLE ........................................................................................... 4-1
JACKING UP THE VEHICLE ..................................................... 4 - 2 ~ 4 - 3
K KEYS ... .......................................................................................................... 1-4
L LIMITED-SLIP DIFFERENTIAL ........................................................... 3-18
LOADING .................................................................................................. 3-12
LOCKING USING THE KEY .................................................................. 1-9
LOW FUEL WARNING LAMP-AMBER ............................................... 2-9
LUBRICATION CHART ................................................................ 9 - 3 ~ 9 - 4
LUMBAR SUPPORT CONTROL ........................................................1-19
M MAINTENANCE .......................................................................................... 1-2
MAKING A FLAT SEAT ........................................................................ 1-23
MANUAL TRANSMISSION ......................................................... 3 - 4 ~ 3 - 5
MEASUREMENT ........................................................................................ 9-1
METER, GAUGE, AND INDICATION/WARNING
LAMP OPERATION ............................................................................. 8-13
MULTI-FUNCTION LIGHT SWITCH ..................................................2-11
MULTIMETER ............................................................................................. 2-4
O ODOMETER ................................................................................................ 2-5
OIL PRESSURE WARNING LAMP-RED ............................................ 2-9
OUTSIDE REAR VIEW MIRROR ......................................................2-21
OUTSIDE REAR VIEW MIRROR HEATER ....................................2-22
OVERDRIVE OFF INDICATOR ............................................................. 2-9
OVERDRIVE SWITCH ............................................................................. 3-8
OVERHEAD AIR CONDITIONING ....................................................2-29P
PARKING BRAKE LEVEL STROKE .................................................8-14
PARKING BRAKE .................................................................................. 3-12
PARKING ..................................................................................... 3-13 ~ 3-14
PASSING SWITCH ................................................................... 2-11 ~ 2-12
POSITIONS OF SWITCHES AND LEVERS ...................................... 2-1
POWER WINDOW .................................................................... 1-17 ~ 1-18
PRE-TENSIONER SEAT BELT ..........................................................1-24
PREVENTIVE MAINTENANCE .............................................................. 6-1
R REAR AIR-CONDITIONING ................................................................. 2-29
REAR HEATER ....................................................................................... 2-28
REAR ROOM LAMP .............................................................................. 2-18
REAR SIDE, QUARTER WINDOW ......................................1-16 ~ 1-17
REAR WINDOW DEFROSTER SWITCH ........................................2-16
REMOTE FUEL-FILLER LID RELEASE ..............................1-15 ~ 1-16
REMOVAL OF WATER FROM THE FUEL FILTER ........4-13 ~ 4-14
REPLACEMENT OF LAMP BULBS ..................................................4-16
ROOF RACK ............................................................................................ 2-21
RUNNING-IN RECOMMENDATIONS .................................................. 1-1
S SEAT BELTS ........................................................................................... 1-23
3-point system .......................................................................... 1-23 ~ 1-24
Lap belts ................................................................................................. 1-25
SEAT BELT REMINDER LIGHT .........................................................2-10
SEAT WARMER ...................................................................................... 1-19
SECOND SEAT .......................................................................... 1-19 ~ 1-20
SIDE VENTILATOR .............................................................................. 2-26
SLIDING WINDOW GLASS ................................................................. 1-17