2003 Hyundai H-1 (Grand Starex) Brake

CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
8-4
I010C01P
1. Windshield washer fluid reservoir cap
2. Engine oil filler cap
3. Brake booster 4. Brake fluid reservoir
5. Engine coolant reservoir
6. Air cleaner
12
34 5
6 79
10
I010C01P-GAT
DIESEL ENGINE ROOM (For 2.5 CRDi TCI)
DIESEL ENGINE ROOM (For 2.5 CRDi TCI) DIESEL ENGINE ROOM (For 2.5 CRDi TCI)
DIESEL ENGINE ROOM (For 2.5 CRDi TCI)
DIESEL ENGINE ROOM (For 2.5 CRDi TCI)
8
7. Power steering fluid reservoir
8. Engine oil level dipstick
9. Battery
1 0 . Fuse and relay box

8-5
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
1. Washer tank cap
2. Engine oil filler cap
3. Engine oil level gauge
4. Brake booster 5. Brake fluid reservoir
6. Radiator cap
7. Air cleaner
8. Power steering oil tank
9. Battery
10. Fuse box
123456
78910
I011A01P-2
I011A02P-GAT
GASOLINE ENGINE ROOM
GASOLINE ENGINE ROOM GASOLINE ENGINE ROOM
GASOLINE ENGINE ROOM
GASOLINE ENGINE ROOM

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

8-7
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
( 9 ) Fuel, engine coolant, oil and exhaust gas leakage
(10) Exterior and interior lamp operation (11) Meter, gauge, and indication/warning lamp operation
(12) Steering wheel free play(13) Clutch pedal free play (14) Brake pedal free play (15) Parking brake lever stroke
Others
Others Others
Others
Others
(1) Wheel rotation
(1) Wheel rotation (1) Wheel rotation
(1) Wheel rotation
(1) Wheel rotation
Every 20,000km (12,000miles)or 12
Every 20,000km (12,000miles)or 12 Every 20,000km (12,000miles)or 12
Every 20,000km (12,000miles)or 12
Every 20,000km (12,000miles)or 12
months, whichever comes first
months, whichever comes first months, whichever comes first
months, whichever comes first
months, whichever comes first
(2) Hinge and latch lubrication
(2) Hinge and latch lubrication (2) Hinge and latch lubrication
(2) Hinge and latch lubrication
(2) Hinge and latch lubrication level surface, stop the engine, and then wait a few moments to allow the engine oil in circula-tion to return to the oil pan to ensure accuratemeasurement. Remove the dipstick and wipe itwith a clean cloth. Reinsert the dipstick andread the oil level, which should always bewithin the range indicated in the figure.
GS80030A
Good
I060A01P-GAT
ENGINE OIL
ENGINE OIL ENGINE OIL
ENGINE OIL
ENGINE OIL
It is important to check the oil level at regular
intervals or before starting a long trip.
This check must be made with the engine
warm but not running. Park the vehicle on a
GS80040A
If the oil level is below the specified limit,
remove the cap located on the cylinder head cover and add enough oil to raise the level towithin the specified range. Be sure to use thespecified engine oil and do not mix varioustypes of oil. Also, avoid mixing different makesof oil together if possible. After adding oil, closethe cap securely.
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
Be careful not to touch the hot exhaust
Be careful not to touch the hot exhaust Be careful not to touch the hot exhaust
Be careful not to touch the hot exhaust
Be careful not to touch the hot exhaust manifold.
manifold. manifold.
manifold.
manifold. CAUTION:
CAUTION: CAUTION:
CAUTION:
CAUTION:
Avoid overfilling, or the engine could be
Avoid overfilling, or the engine could be Avoid overfilling, or the engine could be
Avoid overfilling, or the engine could be
Avoid overfilling, or the engine could bedamaged.
damaged. damaged.
damaged.
damaged.
NOTE:
NOTE: NOTE:
NOTE:
NOTE:
Check the oil level on the dipstick once
Check the oil level on the dipstick once Check the oil level on the dipstick once
Check the oil level on the dipstick once
Check the oil level on the dipstick onceagain after adding the oil.
again after adding the oil. again after adding the oil.
again after adding the oil.
again after adding the oil.
I070A05P-GATSelection of engine oil
Selection of engine oil Selection of engine oil
Selection of engine oil
Selection of engine oil (1) Use engine oil conforming to the following
API classification. Gasoline Engine
Europe : SG, SG/CD, SH or SH/CDExcept Europe : SE or above
Diesel Engine 2.6 N/A : CF-4 or above2.5 4D56 T/C or TCI : CF-4 or above
2.5 CRDi TCI : CE or above
(2) Select engine oil of the proper SAE viscos- ity number according to the atmospheric temperature. Recommened viscosity is given in the fol- lowing drawing.

CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
8-10 I100A02P-GAT
BRAKE FLUID
BRAKE FLUID BRAKE FLUID
BRAKE FLUID
BRAKE FLUID
I100A01P-GAG
MAX MIN
Check the brake fluid level in the reservoir. The brake fluid level must be between the "MAX" and "MIN" marks on the reservoir.The fluid level falls slightly with wear of thebrake pads but it does not indicate any abnor-mality. If the brake fluid level falls markedly in a short time, it indicates leaks from the brake system.In such a case, have your vehicle checked byan authorized HYUNDAI dealer. Use SAE J1703 (or DOT3 or DOT 4) or equiva-lent type brake fluid. On a vehicle with the brake fluid warning lamp, the brake fluid level is monitored by a float.When the brake fluid level falls to below the"MIN" mark, the brake fluid warning lamp lightsup.
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
(1)(1)
(1)(1)
(1) Use only the specified brake fluid. Also,
Use only the specified brake fluid. Also, Use only the specified brake fluid. Also,
Use only the specified brake fluid. Also,
Use only the specified brake fluid. Also,
the additives in different brands may
the additives in different brands may the additives in different brands may
the additives in different brands may
the additives in different brands may
result in a chemical reaction when mixed
result in a chemical reaction when mixed result in a chemical reaction when mixed
result in a chemical reaction when mixed
result in a chemical reaction when mixed
together, so avoid mixing different
together, so avoid mixing different together, so avoid mixing different
together, so avoid mixing different
together, so avoid mixing different
brands if possible.
brands if possible. brands if possible.
brands if possible.
brands if possible.
(2)(2)
(2)(2)
(2) Use extreme caution in filling the brake
Use extreme caution in filling the brake Use extreme caution in filling the brake
Use extreme caution in filling the brake
Use extreme caution in filling the brake
fluid because it is toxic and corrosive,
fluid because it is toxic and corrosive, fluid because it is toxic and corrosive,
fluid because it is toxic and corrosive,
fluid because it is toxic and corrosive,
and it can harm your eyes and damage
and it can harm your eyes and damage and it can harm your eyes and damage
and it can harm your eyes and damage
and it can harm your eyes and damage
painted surface. If the fluid gets in your
painted surface. If the fluid gets in your painted surface. If the fluid gets in your
painted surface. If the fluid gets in your
painted surface. If the fluid gets in your
eyes, flush your eyes with clean water.
eyes, flush your eyes with clean water. eyes, flush your eyes with clean water.
eyes, flush your eyes with clean water.
eyes, flush your eyes with clean water.
I110A01P-GAT CLUTCH FLUID (If installed)
CLUTCH FLUID (If installed) CLUTCH FLUID (If installed)
CLUTCH FLUID (If installed)
CLUTCH FLUID (If installed)
In the case of vehicles with the hydraulic oper- ating clutch, the reservoir for the clutch fluidalso serves as the reservoir for the brake fluid.See the paragraph on the brake fluid.
Irritation to eyes or skin from contact
Irritation to eyes or skin from contact Irritation to eyes or skin from contact
Irritation to eyes or skin from contact
Irritation to eyes or skin from contact
with electrolyte requires immediate med-
with electrolyte requires immediate med- with electrolyte requires immediate med-
with electrolyte requires immediate med-
with electrolyte requires immediate med-
ical attention.
ical attention. ical attention.
ical attention.
ical attention.
(5)(5)
(5)(5)
(5)
If the battery is to be quick-charged, first
If the battery is to be quick-charged, first If the battery is to be quick-charged, first
If the battery is to be quick-charged, first
If the battery is to be quick-charged, first
disconnect the battery cables.
disconnect the battery cables. disconnect the battery cables.
disconnect the battery cables.
disconnect the battery cables.
(6)(6)
(6)(6)
(6) In order to prevent a short circuit, be
In order to prevent a short circuit, be In order to prevent a short circuit, be
In order to prevent a short circuit, be
In order to prevent a short circuit, be
sure to disconnect the negative (-) ter-
sure to disconnect the negative (-) ter- sure to disconnect the negative (-) ter-
sure to disconnect the negative (-) ter-
sure to disconnect the negative (-) ter-
minal before doing anything else.
minal before doing anything else. minal before doing anything else.
minal before doing anything else.
minal before doing anything else.
I090C01P-GAT
Disconnection and connection
Disconnection and connection Disconnection and connection
Disconnection and connection
Disconnection and connection
Never disconnect the battery while the engine
is running; doing so could damage the vehicle’selectrical components. First disconnect thenegative terminal and then the positive termi-nal. When connecting the battery, first connectthe positive terminal and then the negativeterminal.
CAUTION:
CAUTION: CAUTION:
CAUTION:
CAUTION:
(1)(1)
(1)(1)
(1)
Keep the terminals clean. After the bat-
Keep the terminals clean. After the bat- Keep the terminals clean. After the bat-
Keep the terminals clean. After the bat-
Keep the terminals clean. After the bat-
tery is connected, apply terminal protec-
tery is connected, apply terminal protec- tery is connected, apply terminal protec-
tery is connected, apply terminal protec-
tery is connected, apply terminal protec-
tion grease. To clean the terminals, use
tion grease. To clean the terminals, use tion grease. To clean the terminals, use
tion grease. To clean the terminals, use
tion grease. To clean the terminals, use
lukewarm water.
lukewarm water. lukewarm water.
lukewarm water.
lukewarm water.
(2)(2)
(2)(2)
(2) Never short-circuit the battery; doing so
Never short-circuit the battery; doing so Never short-circuit the battery; doing so
Never short-circuit the battery; doing so
Never short-circuit the battery; doing so
could cause it to overheat and be dam-
could cause it to overheat and be dam- could cause it to overheat and be dam-
could cause it to overheat and be dam-
could cause it to overheat and be dam-
aged.
aged. aged.
aged.
aged.
(3)(3)
(3)(3)
(3) Do not smoke or bring an open flame
Do not smoke or bring an open flame Do not smoke or bring an open flame
Do not smoke or bring an open flame
Do not smoke or bring an open flame
near the battery; doing so could ignite
near the battery; doing so could ignite near the battery; doing so could ignite
near the battery; doing so could ignite
near the battery; doing so could ignite
the explosive gas generated by the bat-
the explosive gas generated by the bat- the explosive gas generated by the bat-
the explosive gas generated by the bat-
the explosive gas generated by the bat-
tery.
tery. tery.
tery.
tery.
(4)(4)
(4)(4)
(4) The battery electrolyte is extremely caus-
The battery electrolyte is extremely caus- The battery electrolyte is extremely caus-
The battery electrolyte is extremely caus-
The battery electrolyte is extremely caus-
tic. Do not allow it to come in contact
tic. Do not allow it to come in contact tic. Do not allow it to come in contact
tic. Do not allow it to come in contact
tic. Do not allow it to come in contact
with your eyes, skin, clothing, or the
with your eyes, skin, clothing, or the with your eyes, skin, clothing, or the
with your eyes, skin, clothing, or the
with your eyes, skin, clothing, or the
painted surfaces of the vehicle.
painted surfaces of the vehicle. painted surfaces of the vehicle.
painted surfaces of the vehicle.
painted surfaces of the vehicle.
Spilled electrolyte should be flushed im-
Spilled electrolyte should be flushed im- Spilled electrolyte should be flushed im-
Spilled electrolyte should be flushed im-
Spilled electrolyte should be flushed im-
mediately with ample amounts of water.
mediately with ample amounts of water. mediately with ample amounts of water.
mediately with ample amounts of water.
mediately with ample amounts of water.
o Charge batteries only in a well ventilated
area.
o Do not permit flames, sparks or smoking in the area.
o Keep children away from the area.

8-11
CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
I120D02P-GAT To Check the
To Check the To Check the
To Check the
To Check the T ransmission
Fluid Level
Fluid Level Fluid Level
Fluid Level
Fluid Level
D060A01P-GAG
Button
Park the vehicle on level ground with the park-
ing brake engaged. When the transmission fluid level is checked, the transmission fluidshould be at normal operating temperature andthe engine idling.
While the engine is idling, apply the brakes and
move the gear selector lever from "P" to eachof its other positions-"R", "N", "D", "2", "L"-andthen return to "N" or "P" with the engine stillidling:
I120D02P-GAG
Full mark Good
1. Open the hood, being careful to keep hands, long hair and clothing clear of any moving parts.
2. Remove the transmission dipstick, wipe it clean, reinsert the dipstick as far as it will go, then remove it again. Now check thefluid level on the dipstick. It should be in the"HOT" range on the dipstick.
3. If the transmission fluid level is low, use a funnel to add transmission fluid through thedipstick tube until the level reaches the"HOT" range. Do not overfill, otherwise thetransmission could be damaged.
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
The radiator fan is controlled by engine
The radiator fan is controlled by engine The radiator fan is controlled by engine
The radiator fan is controlled by engine
The radiator fan is controlled by engine
coolant temperature and may sometimes
coolant temperature and may sometimes coolant temperature and may sometimes
coolant temperature and may sometimes
coolant temperature and may sometimes
operate even after the ignition key has even
operate even after the ignition key has even operate even after the ignition key has even
operate even after the ignition key has even
operate even after the ignition key has even
turned off. Use extreme caution when work-
turned off. Use extreme caution when work- turned off. Use extreme caution when work-
turned off. Use extreme caution when work-
turned off. Use extreme caution when work-
ing near the blades of the cooling fan, so
ing near the blades of the cooling fan, so ing near the blades of the cooling fan, so
ing near the blades of the cooling fan, so
ing near the blades of the cooling fan, so
that you are not injured by a rotating fan
that you are not injured by a rotating fan that you are not injured by a rotating fan
that you are not injured by a rotating fan
that you are not injured by a rotating fan
blade. As the coolant temperature decreases,
blade. As the coolant temperature decreases, blade. As the coolant temperature decreases,
blade. As the coolant temperature decreases,
blade. As the coolant temperature decreases,
I120A01P-GAT
CHECKING THE AUTOMATIC
CHECKING THE AUTOMATIC CHECKING THE AUTOMATIC
CHECKING THE AUTOMATIC
CHECKING THE AUTOMATIC
TRANSMISSION FLUID (If installed)
TRANSMISSION FLUID (If installed) TRANSMISSION FLUID (If installed)
TRANSMISSION FLUID (If installed)
TRANSMISSION FLUID (If installed)
Transmission fluid in the automatic transmis-
sion should be changed at those intervals speci-fied in the vehicle maintenance schedule inSection 6.
I120B01P-GATRecommended Fluid
Recommended Fluid Recommended Fluid
Recommended Fluid
Recommended Fluid
Your Hyundai automatic transmission is specially
designed to operate with " DIAMOND ATF
DEXRON II" or "DIAMOND ATF SP I" type
fluid.
I120C02P-GATAA
AA
A
utomatic
utomatic utomatic
utomatic
utomatic transmission
fluid capacity
fluid capacity fluid capacity
fluid capacity
fluid capacity
The fluid capacity of the automatic transmis-
sion will be found on page 9-4.
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
The transmission fluid level should be
The transmission fluid level should be The transmission fluid level should be
The transmission fluid level should be
The transmission fluid level should be checked when the engine is at normal oper-
checked when the engine is at normal oper- checked when the engine is at normal oper-
checked when the engine is at normal oper-
checked when the engine is at normal oper-
ating temperature. This means that the en-
ating temperature. This means that the en- ating temperature. This means that the en-
ating temperature. This means that the en-
ating temperature. This means that the en-
gine, radiator, exhaust system etc., are very
gine, radiator, exhaust system etc., are very gine, radiator, exhaust system etc., are very
gine, radiator, exhaust system etc., are very
gine, radiator, exhaust system etc., are very
hot. Exercise great care not to burn yourself
hot. Exercise great care not to burn yourself hot. Exercise great care not to burn yourself
hot. Exercise great care not to burn yourself
hot. Exercise great care not to burn yourself
during this procedure.
during this procedure. during this procedure.
during this procedure.
during this procedure.

CONSUMER INFORMATION
CONSUMER INFORMATION CONSUMER INFORMATION
CONSUMER INFORMATION
CONSUMER INFORMATION
8-14 I230A01P-GAT
PARKING BRAKE LEVER STROKE
PARKING BRAKE LEVER STROKE PARKING BRAKE LEVER STROKE
PARKING BRAKE LEVER STROKE
PARKING BRAKE LEVER STROKE
D030A01P-1
Pull the parking brake lever all the way up to
check the number of "clicks" that the ratchet makes. One click represents a lever movementof one notch. The lever should move the speci-fied number of notches for normal brake appli-cation.
o Parking brake lever stroke; 5 to 7 notches
If the parking brake lever stroke is not within
the standard range, have the brake lever ad-justed at an authorized HYUNDAI dealer.
Stop the engine, depress the brake pedal sev-eral times, and press down the pedal with yourfingers until initial resistance is felt. This dis-tance should be within the specified range.Free play : 3 to 8 mm (0.1 to 0.3 in.) If the brake pedal free play is not within the standard range, have the brake pedal adjustedat an authorized HYUNDAI dealer.
I220A01P-GAT
BRAKE PEDAL FREE PLAY
BRAKE PEDAL FREE PLAY BRAKE PEDAL FREE PLAY
BRAKE PEDAL FREE PLAY
BRAKE PEDAL FREE PLAYGS80170A
3 ~ 8 mm (0.1 ~ 0.3 in.)
GS80160A
6 ~ 13 mm (0.2 ~ 0.5 in.)
I210A01P-GAT
CLUTCH PEDAL FREE PLAY
CLUTCH PEDAL FREE PLAY CLUTCH PEDAL FREE PLAY
CLUTCH PEDAL FREE PLAY
CLUTCH PEDAL FREE PLAY Press down the clutch pedal with your fingers until initial resistance is felt. This distance shouldbe within the specified range. Free play : 6 to 13 mm (0.2 to 0.5 in.)If the clutch pedal free play is not within the standard range, have the clutch pedal adjustedat an authorized HYUNDAI dealer.

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