2003 Hyundai H-1 (Grand Starex) fuel pump

IN CASE OF EMERGENCY
IN CASE OF EMERGENCY IN CASE OF EMERGENCY
IN CASE OF EMERGENCY
IN CASE OF EMERGENCY
4-13
E090A01P-GATBLEEDING THE FUEL SYSTEM
BLEEDING THE FUEL SYSTEM BLEEDING THE FUEL SYSTEM
BLEEDING THE FUEL SYSTEM
BLEEDING THE FUEL SYSTEM
E090A01P
The fuel system should be bled to remove air as described in the illustration if the fuel supply isexhausted during travel, when the fuel filter isreplaced, or if the vehicle is not used for a longtime.
1. Loosen the air plug at the top of the fuel filter.
2. Pump the hand pump until there are no more bubbles in the fuel coming out of the air plug. When doing this, place a cloth around the airplug to prevent the escaping fuel from spew-ing about.
3. Tighten the air plug when there are no more bubbles in the fuel.
E100A01P-GATREMOVAL OF WATER FROM THE
REMOVAL OF WATER FROM THE REMOVAL OF WATER FROM THE
REMOVAL OF WATER FROM THE
REMOVAL OF WATER FROM THE
FUEL FILTER
FUEL FILTER FUEL FILTER
FUEL FILTER
FUEL FILTER
GS40310ALoosen
Drain plug
If the fuel filter warning lamp illuminates during driving, it indicates that water has accumulatedin the fuel filter. If this occurs, remove the wateras described below.
1. Loosen the drain plug at the bottom of the fuel filter.
GS40320A
Pump
4. Continue pumping until the hand pump be-
comes stiff.
5. Finally, check to be sure that there is no leakage of fuel. If in doubt, consult your nearest authorized HYUNDAI dealer.
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
(1)(1)
(1)(1)
(1) Do not smoke or have any other open
Do not smoke or have any other open Do not smoke or have any other open
Do not smoke or have any other open
Do not smoke or have any other open
flame near the vehicle while bleeding the
flame near the vehicle while bleeding the flame near the vehicle while bleeding the
flame near the vehicle while bleeding the
flame near the vehicle while bleeding the
fuel system.
fuel system. fuel system.
fuel system.
fuel system.
(2)(2)
(2)(2)
(2) Be sure to carefully clean away any fuel
Be sure to carefully clean away any fuel Be sure to carefully clean away any fuel
Be sure to carefully clean away any fuel
Be sure to carefully clean away any fuel
which spilled onto nearby parts coming
which spilled onto nearby parts coming which spilled onto nearby parts coming
which spilled onto nearby parts coming
which spilled onto nearby parts coming
out of the air plug, because such accu-
out of the air plug, because such accu- out of the air plug, because such accu-
out of the air plug, because such accu-
out of the air plug, because such accu-
mulations of fuel might ignite and cause
mulations of fuel might ignite and cause mulations of fuel might ignite and cause
mulations of fuel might ignite and cause
mulations of fuel might ignite and cause
a fire.
a fire. a fire.
a fire.
a fire.
E090A02P

IN CASE OF EMERGENCY
IN CASE OF EMERGENCY IN CASE OF EMERGENCY
IN CASE OF EMERGENCY
IN CASE OF EMERGENCY
4-14 The following points should be observed:
1. Both batteries must be 12V. The capacity
(Ah) of the battery supplying current should not be significantly below that of the dis-charged battery.
2. Use only heavy-duty jumper cables.
3. A discharged battery can freeze. A frozen battery must be thawed out before connect- ing the jumper cables.
4. There should be no contact between the two vehicles; otherwise current may flow whenthe positive terminal is connected.
5. The discharged battery must be correctly connected to the vehicle electrical system.
6. Run the engine of the vehicle supplying current.
7. Connect the jumper cables as follows:
(1) Connect one end of one jumper cable to the positive terminal of the flat battery, and the other end to the positive terminal of thebooster battery.
(2) Connect one end of the other jumper cable to the negative terminal of the booster bat-tery, and the other end to the engine blockof the vehicle with the flat battery at the pointfarthest from the battery.
GS40330A
E110A02P-GAG
If the engine cannot be started because the battery is weak or dead, the battery from an-other vehicle can be used with jumper cables tostart the engine.
E110A01P-GAT
EMERGENCY STARTING
EMERGENCY STARTING EMERGENCY STARTING
EMERGENCY STARTING
EMERGENCY STARTING
CAUTION:
CAUTION: CAUTION:
CAUTION:
CAUTION:
Do not attempt to start the engine by pulling
Do not attempt to start the engine by pulling Do not attempt to start the engine by pulling
Do not attempt to start the engine by pulling
Do not attempt to start the engine by pulling
or pushing the vehicle.
or pushing the vehicle. or pushing the vehicle.
or pushing the vehicle.
or pushing the vehicle.
2. Operate the hand pump slowly 6 or 7 times
in order to force the water out through thedrain plug.
3. Tighten the drain plug when water no longer comes out.
4. Loosen the air plug and bleed the air. (Refer to "Bleeding the fuel system".)
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 isstarted.If in doubt, consult your nearest authorizedHYUNDAI dealer.
WARNING:
WARNING: WARNING:
WARNING:
WARNING:
(1)(1)
(1)(1)
(1) Do not smoke or have any other open
Do not smoke or have any other open Do not smoke or have any other open
Do not smoke or have any other open
Do not smoke or have any other open
flame near the vehicle while bleeding the
flame near the vehicle while bleeding the flame near the vehicle while bleeding the
flame near the vehicle while bleeding the
flame near the vehicle while bleeding the
fuel system.
fuel system. fuel system.
fuel system.
fuel system.
(2)(2)
(2)(2)
(2) Be sure to carefully wipe away any water
Be sure to carefully wipe away any water Be sure to carefully wipe away any water
Be sure to carefully wipe away any water
Be sure to carefully wipe away any water
drained out in this manner, because the
drained out in this manner, because the drained out in this manner, because the
drained out in this manner, because the
drained out in this manner, because the
fuel mixed in the water might be ignited
fuel mixed in the water might be ignited fuel mixed in the water might be ignited
fuel mixed in the water might be ignited
fuel mixed in the water might be ignited
and result in a fire.
and result in a fire. and result in a fire.
and result in a fire.
and result in a fire.

6-1
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
90 72RR R I
R R I
DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (GASOLINE) ENGINE OIL/FILTER AIR CLEANER FILTER FUEL FILTERFUEL SYSTEM LEAKSSPARK PLUGVACUUM CRANKCASE VENTILATION HOSETIMING BELT DRIVE BELT (FOR WATER PUMP/ALTERNATOR)
G000A01P-GAT
6.6.
6.6.
6.
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
G010A01P-GAT SCHEDULED MAINTENANCE (EXCEPT EUROPEAN COMMUNITY)
SCHEDULED MAINTENANCE (EXCEPT EUROPEAN COMMUNITY) SCHEDULED MAINTENANCE (EXCEPT EUROPEAN COMMUNITY)
SCHEDULED MAINTENANCE (EXCEPT EUROPEAN COMMUNITY)
SCHEDULED MAINTENANCE (EXCEPT EUROPEAN COMMUNITY)
R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
The following maintenance services must be performed to assure good
vehicle control and performance. Keep receipts for all vehicle services to protect your warranty. Where both kilometers and time are shown, the frequency of service is
determined by whichever occurs first.
70 56R I I I 80 64
R I I II
NO.
1 2 34567 8 KILOMETERS X 1000 MONTHS
60 48
RRR I
R
II
R
5040
R I I I
40 32
R I I I I
30 24
RRR I
R
I
2016
R I I I I
10
8
R I I I
5 4
R
66
66
6

PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
6-2 90 72
RR R I I I
DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL) ENGINE OIL AND FILTER AIR CLEANER FILTERFUEL FILTERVALVE CLEARANCEINJECTION TIMINGTIMING BELT DRIVE BELT (FOR WATER PUMP/ALTERNATOR) ENGINE IDLE SPEEDFUEL SYSTEM LEAKSINJECTION NOZZLE (If exhaust gas includes black smoke)
G020A03P-GAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
80 64
I I I I I I
KILOMETERS X 1000MONTHSNO.
1 23456 7 89
10
Note : (1) For every 6 months or 5,000 km, whichever occurs first : "R" 10
8
I I I 20 16
I I I I I I 3024
RR
I I I 4032
I I I I I I 5040
I I I 60 48
RR III
R III 7056
I I I
5 4
See Note (1)

PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
6-4 DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (GASOLINE) ENGINE OIL AND FILTER (SG OR ABOVE)*AIR CLEANER FILTERFUEL FILTERFUEL SYSTEM LEAKSSPARK PLUG TIMING BELT DRIVE BELT (FOR WATER PUMP/ALTERNATOR)
G040A02P-GAT
SCHEDULED MAINTENANCE (FOR EUROPEAN COMMUNITY ONLY)
SCHEDULED MAINTENANCE (FOR EUROPEAN COMMUNITY ONLY) SCHEDULED MAINTENANCE (FOR EUROPEAN COMMUNITY ONLY)
SCHEDULED MAINTENANCE (FOR EUROPEAN COMMUNITY ONLY)
SCHEDULED MAINTENANCE (FOR EUROPEAN COMMUNITY ONLY)
Where both kilometers and time are shown, the frequency of service is determined by whichever occurs first.
The following maintenance services must be performed to assure goodvehicle control and performance. Keep receipts for all vehicle services toprotect your warranty. R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
NO.
1 2345 6 7KILOMETERS X 1000 MONTHS
* SF or LOWER : every 10,000 km or 6 months "R".
R
7.5 6 90 72
RRR I
RR I
15 12
R I I 30 24
RR I
R
I 4536
R I
R
I 6048
RR I
R I
R 7560
R I I

6-5
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
90 72R R I
R II
R II I
DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE ( EXCEPT 2.5 CRDi DIESEL )
ENGINE OIL AND FILTER
AIR CLEANER FILTER FUEL SYSTEM LEAKS FUEL FILTER VALVE CLEARANCEINJECTION TIMINGTIMING BELTDRIVE BELT (FOR WATER PUMP/ALTERNATOR) ENGINE IDLE SPEED
INJECTION NOZZLE (I f exhaust gas includes black smoke)
G050A03P-GAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
NO.
1 23 4 5678 9
10KILOMETERS X 1000 MONTHS75 60
R I I I I
60 48
R R I
R III
R I I
4536
R I I I I
30 24
R R I
R II I I I
1512
R I I I I
7.5
6
R

PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
6-6 90 72
RRR I
RR I
DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (2.5 CRD i DIESEL ONLY)
ENGINE OILENGINE OIL FILTERAIR CLEANER FILTERFUEL SYSTEM LEAKSFUEL FILTER DRIVE BELT (FOR WATER PUMP/ALTERNATOR)
INJECTION NOZZLE (I f exhaust gas includes black smoke)
G080A01P-GAT R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY
NO.
1 2345 6 7KILOMETERS X 1000 MONTHS75 60RR I
6048
RRR I
R I I
45 36
RR I
3024
RRR I
R
I I
15 12
RR I

6-9
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
G080F01P-GAToo
oo
o
Fuel hose, vapor hose and fuel
Fuel hose, vapor hose and fuel Fuel hose, vapor hose and fuel
Fuel hose, vapor hose and fuel
Fuel hose, vapor hose and fuel
filler cap
filler cap filler cap
filler cap
filler cap
The fuel hose, vapor hose and fuel filler cap
should be inspected at those intervals specified in the maintenance schedule. Make sure that anew fuel hose, vapor hose or fuel filler cap iscorrectly replaced. Consult your Hyundai dealerif you have any questions.
G080G01P-GAToo
oo
o Air cleaner filter
Air cleaner filter Air cleaner filter
Air cleaner filter
Air cleaner filter
A genuine Hyundai part is recommended forreplacement of the air cleaner filter. G080H01P-GAT
oo
oo
o Spark plugs
Spark plugs Spark plugs
Spark plugs
Spark plugs
Make sure to install new spark plugs of the correct heat range. G080I01P-GAT
oo
oo
o
Drive belts
Drive belts Drive belts
Drive belts
Drive belts
Inspect all drive belts (water pump and alterna- tor) for evidence of cuts, cracks, excessivewear or oiliness, and replace if necessary.Drive belts should be checked periodically forproper tension and adjusted as necessary.
G080D01P-GAT
oo
oo
o Fuel filter
Fuel filter Fuel filter
Fuel filter
Fuel filter
A clogged filter can limit the speed at which the
vehicle may be driven, damage the emissionsystem and cause hard starting. If an exces-sive amount of foreign matter accumulates inthe 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.
G080A01P-GAT
EXPLANATION OF SCHEDULED
EXPLANATION OF SCHEDULED EXPLANATION OF SCHEDULED
EXPLANATION OF SCHEDULED
EXPLANATION OF SCHEDULED
MAINTENANCE ITEMS
MAINTENANCE ITEMS MAINTENANCE ITEMS
MAINTENANCE ITEMS
MAINTENANCE ITEMS
oo
oo
o
Engine oil and filter
Engine oil and filter Engine oil and filter
Engine oil and filter
Engine oil and filter
The engine oil and filter should be changed at
those intervals specified in the maintenanceschedule. If the vehicle is being driven in se-vere conditions, more frequent oil and filterchanges are required.
G080B01P-GAT oo
oo
o Valve clearances (DIESEL)
Valve clearances (DIESEL) Valve clearances (DIESEL)
Valve clearances (DIESEL)
Valve clearances (DIESEL)
An incorrect valve clearance will not only result
in rough engine operation, but will also causeexcessive noise and reduced engine output.
Inspect valve clearance and adjust as required
while the engine is hot.
Valve-to-rocker arm clearance:
Valve-to-rocker arm clearance: Valve-to-rocker arm clearance:
Valve-to-rocker arm clearance:
Valve-to-rocker arm clearance: DIESEL:
Hot ............................ 0.25 mm (0.0098 in.) Cold ............................ 0.15 mm (0.0059 in.)
G080C01P-GAT oo
oo
o Fuel lines and connections
Fuel lines and connections Fuel lines and connections
Fuel lines and connections
Fuel lines and connections
Check the fuel lines and connections for leak-
age and damage. Replace any damaged or leaking parts immediately. G080E01P-GAT
oo
oo
o Vacuum and crankcase
Vacuum and crankcase Vacuum and crankcase
Vacuum and crankcase
Vacuum and crankcase
ventilation hoses
ventilation hoses ventilation hoses
ventilation hoses
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 examiningthose hose surfaces nearest to high heatsources, 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 componentwhich might cause heat damage or mechanicalwear. Inspect all hose connections, such asclamps and couplings, to make sure they aresecure, and that no leaks are present. Hosesshould be replaced immediately if there is anyevidence of deterioration or damage.