2004 Hyundai Coupe maintenance

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SG140D1-E Off Season Maintenance The air conditioning must be run for ten minutes or so weekly during peri- ods when the system would not nor- mally be used to ensure that thecompressor and seals are lubricated. If this precaution is not observed the compressor seals may become stuckto the compressor shaft and dam- aged when the system is next used resulting in a loss of refrigerant anddamage to the compressor. SG140B1-E
Compressor Drive Belt The air conditioning compressor drive
belt should be checked to ensurefreedom from damage or excessive wear and correct tension. The belt tension is correct when the belt de-flects by about 0.3 inches (8 mm) when a force of 98 N is applied to the belt halfway between the compressorand crankshaft pulleys. Adjustment of the belt should be entrusted to a Hyundai dealer.
Crankshaft pulley HTB219
A/C
Tension pulley 8mm (0.315 in.)
1.6L / 2.0L
G190A02B
A/C comp.
Crankshaft pulley
Power steering
Auto tensioner
Generator
2.7 L

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CHANGING THE POLLEN FILTER
G145A02GK-EAT
(In front of blower unit)(Not all models)
The pollen filter is located in front of the blower unit behind the glove box.It helps to decrease the amount ofpollutants entering the car.
2. Open the glove box and removethe mounting screws on the upside of the glove box.
1. Remove the mounting screws on the downside of the glove box. 4. Replace the pollen filter with a new
one.
5. Installation is the reverse order of disassembly.
CAUTION:
Be sure to install the pollen filter in the direction of the arrow sign. Otherwise, it may cause noise or deterioration.
HGK2111-E HGK2112-E HGK2114-E
HGK2115-E
3. Remove the filter cover.

6OWNER MAINTENANCE
26CHECKING THE FREE-PLAY
SG150A1-E STEERING WHEEL Steering wheel freeplay should be checked to ensure that the specifiedvalue is not exceeded. 1.18in. (30 mm)SG160A1-E
CLUTCH PEDAL
The clutch pedal freeplay should be
checked against the specified value. If the freeplay is not correct, the clutch should be adjusted by a Hyundai dealer. 0.24 ~ 0.51 in. (6 ~ 13 mm)
SG170A1-E
BRAKE PEDAL
The brake pedal freeplay should be
checked with the engine turned off. The pedal to floor clearance should be checked with the engine running and a load of 490 N applied to thepedal. If either value is incorrect, the necessary adjustment should be per- formed by a Hyundai dealer. Pedal tofloor clearance: 1.97 in. (50 mm) 0.12 ~ 0.31 in. (3 ~ 8 mm)
HGK5019 G160A01E HXGS508

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27CHECKING BRAKE PEDAL CLEARANCE
G180A01A-EAT You need a helper to check the brake pedal clearance. With the engine run- ning, have your helper press down onthe brake pedal several times and then hold it down with a force of about 490N (50 kg, 110 lbs). The brakepedal clearance is the distance from the top surface of the brake pedal to the asphalt sheeting under the floormat. If the brake pedal clearance is not within the limits specified in the illustration, have it inspected by yourHyundai dealer and adjusted or re- paired if necessary. 1.78 in.(45.1 mm)
YG190A1-E
CHECKING ENGINE DRIVE BELTS
If a belt is loose, adjust it by:
1. Loosen the adusting bolts justenough so that the components can be moved.
2. Whilst pulling outward on the pry bar or screw driver, test the beltdeflection with your thumb.
3. After tightening the adjusting bolts,
be sure to recheck the belt tension.Overtightening drive belts can cause excessive wear and failure in driven components and belts.
G180A01L
Tension pulleyGenerator
G190A01GK
Power steering
Water pump pulley
A/Ccomp.
2.0L G190A02B
A/C comp.
Crankshaft pulley
Power steering
Auto tensioner
Generator
2.7LWater Pump Pulley
Alternator Pulley
Pulley Crankshaft Pulley 0.2~0.24 in.(5.1~6 mm)
HTB186
1.6L
Crankshaft pulley

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G200A01E
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FUSIBLE LINKS
SG200A1-E The fusible link prevents damage to the wiring harness in the event of an electrical system malfunction. Failureof a fusiblelink is indicative of a seri- ous overload condition having oc- curred and therefore the electricalsystem should be checked by a Hyundai dealer before a replacement link is fitted. WARNING:
Under no circumstances should a
fusible link be replaced with any-thing other than a new link of thesame rating. The use of higher rated links or other means of con- necting the circuit will create apotential fire hazard.
Melted SG200B2-E
INDIVIDUAL CIRCUIT FUSES
The fuse box containing the individual
circuit fuses is located on the lowerportion of the dashboard adjacent to the bonnet release. The fuse box cover is removed by pushing lightlyand then releasing the lid. A fuse rating grid will be found on the re- verse side of the cover. In the eventof fuse failure, the fuse should be replaced with one of equivalent rat- ing. A fuse removal tool is providedwithin the fuse box to facilitate re- placement.
Good
HGK4003-E

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In the event of a replacement fuse failing shortly after installation a mal- function within the circuit protected bythat fuse is indicated. The circuit should be checked by a Hyundai dealer at the first available opportu-nity. WARNING:
The use of replacement fuses hav-ing a higher rating than specified or other means of connecting the circuit will create a potential firehazard. Good
HXDFL1026-1
G200B02L
Burned out
NOTE: See page 6-41 for the fuse panel
descriptions.
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BATTERY MAINTENANCE
SG210A1-E
WARNING:
Motor vehicle batteries contain sulphuric acid which is corrosiveand poisonous. Hydrogen gas is emitted from the battery which is explosive when combined with oxygen. The following precautions must be strictly observed to avoid personal injury or damage to the vehicle. D010B01GK

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o If battery electrolyte is spilled onto
skin or into eyes, the effected area must be flushed with copious amounts of water and medical assis-tance sought.
o If battery electrolyte is ingested, copious amounts of water or milkfollowed by an ant-acid (raw egg ormilk of magnesia) must be drunk. Vomiting should not be induced and medical assistance must besought.
o Batteries must only be charged in well venti-lated areas from which naked lights or sources of sparks are excluded.
o Ensure that children, pets or other unautho-rized persons are keptaway from batteries.
o Do not allow anything to bridge the
positive (+) and negative (-) termi-nals of the battery.
o Never invert the battery.
The battery fitted during production isof the "Maintenance Free" type.
ELECTRIC COOLING FANS
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YG210A1-E
WARNING:
The cooling fan is controlled by engine coolant temperature and may sometimes operate even whenthe engine is not running. Do not touch the radiator fan until it is completely stopped.As the coolant temperature de-creases the fan will automaticallyshut off. This is a normal condi- tion.
Checking Engine Cooling Fan The engine cooling fan should auto- matically come on if the engine cool-ant temperature is high.
Checking Condenser Cooling Fan The condenser cooling fan (in front of the condenser) should come on auto- matically whenever the air conditioneris in operation.
POWER STEERING HOSES
YG220A1-E It is suggested that you check the power steering hose connections for fluid leakage at those intervals speci- fied in the vehicle maintenance sched-ule in Section 5. The power steering hoses should be replaced if there are severe surface cracking, pulling, scuff-ing or worn spots. Deterioration of the hoses could cause premature failure. NOTE: The power steering pump may be noisy when the engine is firststarted in the extreme cold (-4°F). This noise is not abnormal and will stop as the engine warms up.If the power steering pump contin- ues to be noisy after the engine has warmed up, have it inspectedby your Authorized Hyundai Dealer.

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HGK5011
G230A03A-EAT
Power Steering Fluid Level Fluid Recommendation
Only automatic transaxle fluid meet-
ing the specification of PSF-3 or ATF DEXRON 2 should be used in thepower steering system.
The power steering fluid level should
be checked regularly.
To check the power steering fluid
level, be sure the ignition is "OFF",then check to make certain that thepower steering fluid level is between the "MAX" and "MIN" level markings on the fluid reservoir.
NOTE: Do not check whilst the engine is
running. Do not start when power steering fluid reservoir is empty.High Beam
G290A01GK
G290A01GK-EAT HEADLIGHT AIMING AD- JUSTMENT
Before performing aiming adjustment, make sure of the following.
G290A02GK
Low Beam
Horizontal aiming Verticalaiming
Horizontal aiming Vertical aiming