2003 Hyundai H-1 (Grand Starex) water pump

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.

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