2003 Hyundai Terracan manual transmission

WHAT TO DO IN AN EMERGENCY 3-9
D060J01A-AAT AFTER CHANGING WHEELS If you have a tire gauge, remove the valve cap and check the air pressure. If the pressure is lower than recommended, drive slowly to the nearest service station and inflate to the correct pressure. If it is too high, adjust it until it is correct. Always reinstall the valve cap after checking or adjusting tire pressure. If the cap is not replaced, air may leak from the tire. If you lose a valve cap, buy another and install it as soon as possible. After you have changed wheels, always secure the flat tire in its place and return the jack, jack handle, and tools to their proper storage loca- tions.
D060J01HPD080A02A-GAT IF YOUR CAR MUST BE TOWED
o OK for 4WD
o OK for Automatic or Manual
Transmission Equipped Vehicle D080A01HP
CAUTION:Your car can be damaged if towed incor- rectly! If your car has to be towed, it should be done by your Hyundai dealer or a commercial tow truck service. This will help assure that your car is not damaged in towing. Also, professionals are gen- erally aware of local laws governing towing. In any case, rather than risk damage to your car, it is suggested that you show this information to the tow truck operator. Be sure that a safety chain system is used and that all local laws are ob- served. D080B01HP-GAT Towing a Car With Manual Transmis- siono Not OK for 4WD
(OK for Part Time 4WD in 2H Position)
o Not OK for Automatic Transmission Equipped Vehicle
o OK for Manual Transmission D080B01HP
o Be sure that the ignition key is in the "ACC" position. This is necessary to prevent dam- age to the steering lock mechanism, which is not designed to hold the front wheels straight while the car is being towed.
o If any of the loaded wheels or suspension components are damaged, a towing dolly must be used.
CAUTION: Full time 4 Wheel Drive cannot be towed with a tow truck. It must be towed by lifting all 4 wheels.

WHAT TO DO IN AN EMERGENCY
3-10 D120A01A-GAT IF YOU LOSE YOUR KEYS If you lose your keys, many Hyundai dealers can make you a new key if you have your key number. If you lock the keys inside your car and you cannot obtain a new key, many Hyundai dealers can use special tools to open the door for you. Information about the key of immobilizer system (if installed) will be found on page 1-2.
D080D01O-GAT Emergency Towing
D080D01HP For emergency towing when no commercial tow vehicle is available, attach a tow cable, chain or strap to one of the tie-down hooks under the front of your car. Be very careful when attempting this procedure when the vehicle is on any unpaved surface to avoid damage to your vehicle. Nor should towing be attempted if the wheels, drive train, axles, steering or brakes are dam- aged. Before towing, be sure the transmission is in neutral and the key is in "ACC" (with the engine off) or in the "ON" position (with the engine running). A driver must be in the towed car to steer it and operate the brakes. NOTE: To avoid serious damage to your 4WD ve- hicle, limit the towing to 15 km/h (10 mph) and not for more than 1.5 km (1 mile) at ANY TIME.
o OK for 4WD
o OK for Automatic or Manual Transmission
Equipped VehicleD080C02HP
NOTE: Before towing, check the level of the trans- mission fluid. If it is below the "HOT" range on the dipstick, add fluid. If you cannot add fluid, a towing dolly must be used.
D080C01HP-GAT Towing A Car With Automatic Trans- mission
CAUTION: A car with an automatic transmission should never be towed from the front with the rear wheels on the ground. This can cause seri- ous damage to the transmission. If the car must be towed from the front, a towing dolly must be used under the rear wheels.
o If the car is being towed with all four wheels on the ground, it can be towed only from the front. Be sure that the transmission is in neutral. Do not tow at speeds greater than 50 km/h (30 mph) and for more than 25 km (15 miles).
Be sure the steering is unlocked by placing the key in the "ACC" position. A driver must be in the towed vehicle to operate the steering and brakes.
o Not OK for 4WD (OK for Part Time 4WD in 2H Position)
o OK for Automatic or Manual Transmission
Equipped Vehicle with No Damage
D080C01HP

VEHICLE MAINTENANCE REQUIREMENTS 5-1
F010C01HP-GAT Specified Scheduled ProceduresThese are the procedures such as inspections, adjustments and replacements that are listed in the maintenance charts starting on page 5-2. These procedures must be performed at the intervals shown in the maintenance schedule to assure that your warranty remains in effect. Although it is strongly recommended that they be performed by the factory-trained or distribu- tor-trained technicians at your Hyundai dealer, these procedures may be performed at any qualified service facility. It is suggested that genuine Hyundai service parts be used for any required repairs or re- placements. Other parts of equivalent quality such as engine oil, engine coolant, manual or auto transmission oil, brake fluid and so on which are not supplied by Hyundai Motor Com- pany or its distributor may be used without affecting your warranty coverage but you should always be sure these are equivalent to the quality of the original Hyundai parts. Your Ser- vice Passport provides further information about your warranty coverage.
5. VEHICLE
MAINTENANCE
REQUIREMENTS F010E01A-AAT Do-It-Yourself Maintenance If you are mechanically inclined, own a few tools that are required and want to take the time to do so, you can inspect and service a number of items. For more information about doing it your- self, see Section 6.
F010D01A-AAT General ChecksThese are the regular checks you should per- form when you drive your Hyundai or you fill the fuel tank. A list of these items will be found on page 6-4.
F010A01A-GAT MAINTENANCE INTERVALS Service Requirements To assure that you receive the greatest number of kilometers of satisfying operation from your Hyundai, certain maintenance procedures must be performed. Although careful design and en- gineering have reduced these to a minimum, those that are required are of the utmost impor- tance. It is your responsibility to have these mainte-nance procedures performed to comply with the terms of the warranties covering your new Hyundai. The Service Passport supplied with your new vehicle provides further information about these warranties. F010B01A-AAT Maintenance RequirementsThe maintenance required for your Hyundai can be divided into three main areas: o Specified scheduled procedures o General checks o Do-it-yourself maintenance F010F01A-AAT A Few Tips
o Whenever you have your Hyundai serviced,
keep copies of the service records in your glove box. This will help ensure that you can document that the required procedures have been performed to keep your warranties in effect. This is especially important when service is not performed by an authorized Hyundai dealer.
o If you choose to do your own maintenance
and repairs, you may find it helpful to havean official Hyundai Shop Manual. A copy of this publication may be purchased at your Hyundai dealer's parts department.
F020A01Y-GAT SCHEDULED MAINTENANCE RE- QUIREMENTS Inspection should be performed any time a malfunction is experienced or suspected. Re- ceipts for all emission control system services should be retained to demonstrate compliance with conditions of the emissions system war- ranty. For severe usage maintenance requirements, see page 5-6 of this section.
5

VEHICLE MAINTENANCE REQUIREMENTS 5-5
I
R I III I III I I I III
R I
GENERAL MAINTENANCECOOLING SYSTEMCOOLANT MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION FLUID AND FILTERBRAKE HOSES AND LINESBRAKE FLUIDREAR BRAKE DRUMS/LININGS, PARKING BRAKEBRAKE PADS, CALIPERS AND ROTORS EXHAUST PIPE AND MUFFLER SUSPENSION MOUNTING BOLTSSTEERING GEAR BOX, LINKAGE & BOOTS/LOWER ARM BALL JOINT, UPPER ARM BALL JOINTPOWER STEERING PUMP AND HOSESDRIVE SHAFTS AND BOOTS AIR CONDITIONING REFRIGERANT TRANSFER CASE OIL *1AXLE GEAR OIL *1PROPELLAR SHAFT CLEAN, BOLT RETIGHTENAIR FILTER (For Evaporator and Blower Unit)
1 23 4 5 678 9
10 1112 13 14 15161718
F030C04HP-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
Note : (1) FOR EVERY 24 MONTHS OR 45,000 KM, WHICHEVER OCCURS FIRST : "R"
(2) FOR EVERY 12 MONTHS OR 20,000 KM, WHICHEVER OCCURS FIRST : "R"
*1. Transfer Case Oil and Axle Gear Oil should be changed anytime they have been submerged in water.
NO. DESCRIPTION
I
R I III I III I I I III I I15 12 30 24
45 36 60 48
75609072105
84 120
96KILOMETERS X 1000 MONTHS
I
R I I III I III I I I III I I I III I I I I I I I I
I I I II I II I I I I
R I I III I I I I I I I II
R I
R
I I I III I I I III I I I I III I I I I I I I
R
European Community Only Except European Community
See Note (1)Gasoline Engine Diesel Engine
See Note (2)

VEHICLE MAINTENANCE REQUIREMENTS
5- 6 ENGINE OIL AND FILTER (GASOLINE ENGINE) ENGINE OIL AND FILTER (DIESEL ENGINE (2.5 TCI)) ENGINE OIL AND FILTER
(DIESEL ENGINE (2.9 CRDi)) AIR CLEANER FILTER SPARK PLUGS TIMING BELT BRAKE PADS, CALIPERS AND ROTORS REAR BRAKE DRUMS/LININGS/PADS, PARKING BRAKE STEERING GEAR BOX, LINKAGE AND BOOTS/ LOWER ARM BALL JOINT, UPPER ARM BALL JOINT DRIVESHAFTS AND BOOTS MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION FLUID AND FILTER TRANSFER CASE OIL
R R R R
II I I
R R R
European Community Only Except European Community European Community Only Except European Community
A, B, C, F, H C, E B, H D, E, F, G C, D, G, H C, D, G, H C, D, E, F C, D, E, F A, C, D, E, F, G, H, I, J A, C, E, F, G, H, I C, E, G, I
F040A03HP-GAT
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 SEVERE DRIVING CONDITIONS
A - Repeated short distance driving
B - Extensive idling
C - Driving in dusty, rough roads
D - Driving in areas using salt or other corrosive materials or in very cold weather
E - Driving in sandy areas F - More than 50% driving in heavy city traffic during hot
weather above 32°C (90°F)
G - Driving in mountainous areas
H - Towing a trailer
I - Driving for patrol car, taxi, or other commercial use or
vehicle towing
J - Driving over 170 km/h
MAINTENANCE ITEM
European Community OnlyExcept European Community
DRIVING
CONDITION
MAINTENANCE
OPERATION MAINTENANCE
INTERVALS
EVERY 7,500 KM OR 6 MONTHS EVERY 4,000 KM EVERY 3,000 KM EVERY 7,500 KM OR 6 MONTHS EVERY 5,000 KM OR 6 MONTHS MORE FREQUENTLY MORE FREQUENTLY EVERY 60,000 KM OR 48 MONTHS MORE FREQUENTLY MORE FREQUENTLY MORE FREQUENTLY EVERY 15,000 KM OR 12 MONTHS EVERY 100,000 KM EVERY 45,000 KM EVERY 40,000 KM EVERY 100,000 KM

VEHICLE MAINTENANCE REQUIREMENTS 5-7
F060A01A-AAT EXPLANATION OF SCHEDULED MAIN- TENANCE ITEMS F060M01A-AAT o Engine Oil and FilterThe engine oil and filter should be changed at
the intervals specified in the maintenance sched- ule. If the car is being driven in severe condi- tions, more frequent oil and filter changes are required. F060B01A-AAT
o Drive BeltsInspect all drive belts for evidence of cuts, cracks, excessive wear or oil saturation and replace if necessary. Drive belts should be checked periodically for proper tension and adjusted as necessary. F060C01A-AAT
o Fuel Filter A clogged filter can limit the speed at which the vehicle may be driven, damage the emission system and cause hard starting. If an exces- sive amount of foreign matter accumulates in the fuel tank, the filter may require replacement more frequently.After installing a new filter, run the engine for several minutes, and check for leaks at the connections. Fuel filters should be installed by trained technicians.
F060D01A-AAT
o Fuel Lines, Fuel Hoses and Connec-
tions
Check the fuel lines, fuel hoses and connec- tions for leakage and damage. Have a trained technician replace any damaged or leaking parts immediately. F060E01A-AAT
o Timing BeltInspect all parts related to the timing belt for damage and deformation. Replace any dam- aged parts immediately. F060G01A-AAT
o Vapor Hose and Fuel Filler CapThe vapor hose and fuel filler cap should be inspected at those intervals specified in the maintenance schedule. Make sure that a new vapor hose or fuel filler cap is correctly re- placed. F060F01A-AAT
o Vacuum, Crankcase
Ventilation Hoses
Inspect the surface of hoses for evidence ofheat and/or mechanical damage. Hard and brit- tle rubber, cracking, tears, cuts, abrasions, and excessive swelling indicate deterioration. Par- ticular attention should be paid to examine those hose surfaces nearest to high heat sourc- es, such as the exhaust manifold. Inspect the hose routing to assure that thehoses do not come in contact with any heat source, sharp edges or moving component which might cause heat damage or mechanical wear. Inspect all hose connections, such as clamps and couplings, to make sure they are secure, and that no leaks are present. Hoses should be replaced immediately if there is any evidence of deterioration or damage. F060H01A-AAT o Air Cleaner FilterA Genuine Hyundai air cleaner filter is recom- mended when the filter is replaced. F060J01A-AAT o Spark PlugsMake sure to install new spark plugs of the correct heat range. F070C01A-AAT o Engine CoolantThe coolant should be changed at the intervals specified in the maintenance sched- ule. F070D01A-AAT o Manual Transmission OilInspect the manual transmission oil according to the maintenance schedule. NOTE: If the oil level is low, check for possible leaks before adding oil. Do not overfill.

VEHICLE MAINTENANCE REQUIREMENTS
5- 8
F070E01HP-GAT
o Automatic Transmission Fluid and
Filter
The fluid level should be in the "HOT" range of the dipstick, after the engine and transmission are at normal operating temperature. Check the automatic transmission fluid level with the en- gine running and the transmission in neutral, with the parking brake properly applied. Use DEXRON- II or III when adding or changing
fluid. F070F01A-AAT
o Brake Hoses and LinesVisually check for proper installation, chafing, cracks, deterioration and any leakage. Replace any deteriorated or damaged parts immediate- ly. F070G02A-AAT o Brake FluidCheck brake fluid level in the brake fluid reser- voir. The level should be between "MIN" and "MAX" marks on the side of the reservoir. Use only hydraulic brake fluid conforming to DOT 3 or DOT 4. F070H01A-AAT
o Rear Brake Drums/ Linings,
Parking Brake
Check the rear brake drums and linings for scoring, burning, leaking fluid, broken parts, and excessive wear. Inspect the parking brake system including the parking brake lever and cables. For detailed service procedures, refer to the Shop Manual. F070J01A-AAT o Brake Pads, Calipers and RotorsCheck the pads for excessive wear, discs for run out and wear, and calipers for fluid leakage. F070K01A-AAT o Exhaust Pipe and Muffler Visually inspect the exhaust pipes, muffler and hangers for cracks, deterioration, or damage. Start the engine and listen carefully for any exhaust gas leakage. Tighten connections or replace parts as necessary. F070L01A-AAT o Suspension Mounting BoltsCheck the suspension connections for loose- ness or damage. Retighten to the specified torque. F070N01A-AAT
o Power Steering Pump, Belt and
Hoses
Check the power steering pump and hoses for leakage and damage. Replace any damaged or leaking parts immediately. Inspect the power steering belt for evidence of cuts, cracks, ex- cessive wear, oiliness and proper tension. Re- place or adjust it if necessary. F070P01A-AAT o Driveshafts and Boots Check the drive shafts, boots and clamps for cracks, deterioration, or damage. Replace any damaged parts and, if necessary, repack the grease. F070Q01A-AAT
o Air Conditioning RefrigerantCheck the air conditioning lines and connec- tions for leakage and damage. Check air condi- tioning performance according to the relevant shop manual if necessary.
F070M01B-AAT
o Steering Gear Box, Linkage & Boots/
Lower Arm Ball Joint, Upper Arm Ball Joint
With the vehicle stopped and engine off, check for excessive free-play in the steering wheel. Check the linkage for bends or damage. Check the dust boots and ball joints for deterioration, cracks, or damage. Replace any damaged parts.

DO-IT-YOURSELF MAINTENANCE
6-4
G020A01A-AAT GENERAL CHECKS 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 Engine coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level
o Battery condition
o Air filter condition G020B01A-AAT Vehicle Exterior The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut torque
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and body corrosion
o Fluid leaks
o Door and hood lock condition
o Tire pressure and condition (including
spare tire) G020C01A-AAT Vehicle InteriorThe following should be checked each time when the vehicle is driven:
o Lights operation
o Windshield wiper operation
o Horn operation
o Defroster, heating system operation (and air
conditioning, if installed)
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 appears to be functioning incorrect- ly, inspect it carefully and seek assistance from your Hyundai dealer if service is needed. G030A01A-AAT CHECKING THE ENGINE OILEngine oil is essential to the performance and service of the engine. It is suggested that you check the oil level at least once a week in normal use and more often if you are on a trip or driving in severe conditions. G030B03HP-GAT Recommended Oil 1. Gasoline Engine
(1) Select engine oil of the proper SAE viscosity
number according to the atmospheric tem- perature. Recommended viscosity is given in the fol- lowing illustration.
G030B01HP
NOTE: SAE 5W-20 is not recommended for sus- tained high speed vehicle operation.
Gasoline Engine