2003 Hyundai H-1 (Grand Starex) Brake

APPEARANCE CARE
APPEARANCE CARE APPEARANCE CARE
APPEARANCE CARE
APPEARANCE CARE
5-2 Have the underbody checked regularly (au-
tumn and spring) and have additional protec- tion treatment carried out as required. As not allof the commercially available materials aresuitable for use on your vehicle, it is recom-mended that you have this work done at anauthorized HYUNDAI dealer.
When washing the vehicle, especially in winter,
spray the underbody with water to remove dirtand dust which might contain salts, road chemi-cals, etc. Clean the carpeting with a vacuum cleaner andremove any stains with carpet cleaner.Oil and grease can be removed by lightlydabbing with a clean colorfast cloth and ben-zene or spot remover.
F010O01P-GAT
Load weight and driving speed
Load weight and driving speed Load weight and driving speed
Load weight and driving speed
Load weight and driving speed
Remove any luggage, etc., which is not neces-sary from the vehicle. The load weight placedon the roof or towed in a trailer also should notbe excessive. Correctly adjusting the air pressure of the tires before driving under maximum load weight con-ditions and before driving long distances isespecially important. F010P01P-GAT
Tire replacement
Tire replacement Tire replacement
Tire replacement
Tire replacement
Tires which do not meet the size specifications must not be used. Replacement of the tiresmust be made as a set of the two front tires, thetwo rear tires, or all four tires. A mixture of bias-ply tires and radial tires must not be used. Consult an authorized HYUNDAIdealer regarding tire replacement. F010Q01P-GAT
Kerb parking
Kerb parking Kerb parking
Kerb parking
Kerb parking
If the tires strike a kerb or concrete parking barrier, they could be damaged, and this dam-age could become a source of extreme dangerwhen the vehicle is subsequently driven at highspeed. If the vehicle is to be driven or onto akerb or any other such barrier, it should bedriven slowly and at an appropriate angle to thekerb or barrier.
F010J01P-GAT
Engine compartment
Engine compartment Engine compartment
Engine compartment
Engine compartment
Clean the engine compartment at the beginning
and end of winter. Pay particualr attention toflanges, crevices, and peripheral parts wheredust containing road chemicals and other cor-rosive materials might collect.
If salt and other chemicals are used on the
roads in your area, clean the engine compart-ment at least every three months.
F010K01P-GATUpholstery and Interior
Upholstery and Interior Upholstery and Interior
Upholstery and Interior
Upholstery and Interior
To maintain the value of your new vehicle,
handle the upholstery carefully and keep theinterior clean.
Use a vacuum cleaner and brush to clean the
seats. If stained, vinyl and synthetic leathershould be cleaned with an appropriate cleaner,and cloth fabrics can be cleaned with eitherupholstery cleaner or a 3% solution of neutraldetergent in lukewarm water. F010L01P-GAT
Damaged paint
Damaged paint Damaged paint
Damaged paint
Damaged paint
Small cracks and scratches in the paint coatshould be touched up as soon as possible withHYUNDAI paint pencil or spray paint to preventcorrosion. Check body areas facing the road orthe tires especially carefully for damage to thepaint coat caused by flying stones, etc. Thepaint code number for your vehicle can befound on the vehicle information code plate.
F010M01P-GATTarTar
TarTar
Tar
If tar becomes adhered to the vehicle, usespecial tar remover to remove it as soon aspossible. If the tar leaves a stain, polish theaffected area. F010N01P-GAT
Plastic and rubber parts
Plastic and rubber parts Plastic and rubber parts
Plastic and rubber parts
Plastic and rubber parts
Use a soft cloth and wash with water. If neces- sary, a cleaning agent specially designed forplastics can be used. If engine oil, brake fluid,battery fluid, etc., comes in contact with theseparts, wash promptly with water and then usealcohol to remove the stain completely.

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.

8-1
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
1. Windshield washer fluid reservoir cap
2. Engine oil filler cap
3. Engine oil level dipstick
4. Brake booster 5. Brake fluid reservoir
6. Engine coolant reservoir
7. Radiator cap
8. Air cleaner 9. Power steering fluid reservoir
10. Battery
I000A01P-GAT
8.8.
8.8.
8.
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
I010A01P-GAT DIESEL E
DIESEL E DIESEL E
DIESEL E
DIESEL E NGINE
NGINE NGINE
NGINE
NGINE R R
R R
R
OOM (F
OOM (F OOM (F
OOM (F
OOM (F
or 2.6 N/A)
or 2.6 N/A) or 2.6 N/A)
or 2.6 N/A)
or 2.6 N/A)
I010A01P-1
123
45 67
10
9
8
88
88
8

CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
8-2
I010D01P
12 345 67
10
9
8
1. Windshield washer fluid reservoir cap
2. Engine oil filler cap
3. Engine oil level dipstick
4. Brake booster 5. Brake fluid reservoir
6. Engine coolant reservoir
7. Radiator cap
8. Air cleaner 9. Power steering fluid reservoir
10. Battery
1 1 . Fuse and relay box
I010D01P-GAT
DIESEL ENGINE ROOM (For 2.5 4D56 T/C)
DIESEL ENGINE ROOM (For 2.5 4D56 T/C) DIESEL ENGINE ROOM (For 2.5 4D56 T/C)
DIESEL ENGINE ROOM (For 2.5 4D56 T/C)
DIESEL ENGINE ROOM (For 2.5 4D56 T/C)
11

8-3
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
I010B01P
1. Windshield washer fluid reservoir cap
2. Automatic transmission fluid level dipstick (A/T only)
3. Engine oil filler cap
4. Engine oil level dipstick 5. Brake booster
6. Brake fluid reservoir
7. Engine coolant reservoir
8. Air cleaner
9. Power steering fluid reservoir
10. Battery
1 1 . Fuse and relay box
12
3 456 7
8 91
011
I010B01P-GAT
DIESEL ENGINE ROOM (For 2.5 4D56 TCI)
DIESEL ENGINE ROOM (For 2.5 4D56 TCI) DIESEL ENGINE ROOM (For 2.5 4D56 TCI)
DIESEL ENGINE ROOM (For 2.5 4D56 TCI)
DIESEL ENGINE ROOM (For 2.5 4D56 TCI)