2004 Hyundai H-1 (Grand Starex) engine

6VEHICLE MAINTENANCE REQUIREMENTS
10
45 36II
R II I I I I
15 12
II I I I I I I I
G050A04P-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
See Note (2)
KILOMETERS X 1000 MONTHS
NO.
1 2 3 4 5 6 7 8 9
1011 12 13 14 15 16 17 18 19 20 DESCRIPTION
GENERAL MAINTENANCE ENGINE COOLANT MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL TRANSFER CASE OIL REAR AXLE OIL CLUTCH/BRAKE PEDAL FREEPLAY CLUTCH/BRAKE OIL RESERVOIR BRAKE HYDRAULIC FLUID FRONT BRAKE PAD FRONT BRAKE CALIPERS/CYLINDERS/DISC REAR BRAKE DRUMS/LININGS/CYLINDERS HAND BRAKE TIRE CONDITION/PRESSURE EXHAUST SYSTEM/MOUNTING STEERING JOINT/RACK/BOX/OIL LEAKS SUSPENSION JOINT/SEALS FRONT WHEEL BEARING ENGINE COOLANT HOSES BRAKE PIPE CORROSION AIR CONDITIONER FILTER (FOR EVAPOERATOR AND BLOWER UNIT)
75 60
II I I I I I I I 90 72
I
R R I I I I I I I I I I I I I I
6048
II I I I I I I I I I I I I I I I
3024
II I I I I I I I I I I I I I I I
7.5
6
See Note (1)
Note: (1) For every 45,000 KM or 24 months, whichever occurs first : "R"
(2) For every 48,000 KM or 24 months, whichever occurs first : "R"
(3) For every 20,000 KM or 12 months, whichever occurs first : "R"
See Note (3)

6
VEHICLE MAINTENANCE REQUIREMENTS
11
GASOLINE DIESELMore Frequently More Frequently Every 60,000 KM or 48 monthsMore FrequentlyMore FrequentlyEvery 10,000 KM or 6 months More Frequently Every 100,000 KM Every 40,000 KMEvery 45,000 KM Every 7,500 KM or 6 monthsEvery 3,000 KMEvery 4,000 KM (Except 2.5 CRDi)Every 7,500 KM or 6 months (2.5 CRDi only)
ENGINE OIL AND FILTER AIR CLEANER FILTER SPARK PLUGSTIMING BELT BRAKE PADS, CALIPERS, ROTORS REAR BRAKE DRUMS AND LININGSSTEERING GEAR BOX, LINKAGE & BOOTSAIR CONDITIONER FILTER(FOR EVAPORATOR AND BLOWER UNIT)MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL
G070A07P-GAT 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
R R RR
I I I
R R R
SEVERE DRIVING CONDITIONS A - Repeated short distance driving
B - Extensive idling
C - Driving in dusty conditions
D - Driving in areas using salt or other corrosive materials or
in very cold weather
E - Driving in sandy areas
A, B, C, F, H, J C, E B, HD, E, F, GC, D, G, H C, D, G, H C, D, E, F C,EA, C, D, E, F, G, H, I, J A, C, E, F, G, H, I DRIVING
CONDITION
MAINTENANCE INTERVALS
MAINTENANCE
OPERATION
MAINTENANCE ITEM
F - More than 50% driving in heavy city traffic during hot above32°C (90°F)
G - Driving in mountainous areas
H - Towing a trailer or police car, taxi, or commercial type operation
I - Driving for patrol car, taxi, commercial car or vehicle towing
J - Driving over 170 km/h
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
Except E.C For E.C
Except E.C For E.C

6VEHICLE MAINTENANCE REQUIREMENTS
12EXPLANATION OF SCHEDULED MAINTENANCE ITEMS
F060M01A-AAT
o Engine Oil and Filter The engine oil and filter should be changed at those intervals specified in the maintenance schedule. If the ve- hicle is being driven in severe condi-tions, more frequent oil and filter changes are required. G080B02P-GAT
o Valve Clearances (Diesel) An incorrect valve clearance will not only result in rough engine operation, but will also cause excessive noiseand reduced engine output.Inspect valve clearance and adjust asrequired while the engine is hot. G080C02P-GAT
o Fuel Lines and Connections
Check the fuel lines and connections
for leakage and damage. Replace any damaged or leaking parts immediately. G080D01P-GAT
o Fuel Filter
A clogged filter can limit the speed at
which the vehicle may be driven, dam-age the emission system and cause hard starting. If an excessive amountof foreign matter accumulates in the fuel tank, the filter may require re- placement more frequently. After installing a new filter, run the
engine for several minutes, and checkfor leaks at the connections.
!WARNING (Diesel only):
Never work on injection system with
engine running or within 30 sec- onds after shutting off engine. High pressure pump, rail, injectors and high pressure pipes are subject to high pressure even after the engine stopped. The fuel jet produced byfuel leaks may cause serious injury, if it touch the body. People using pacemakers should not move than30cm closer to the ECU or wiring harness within the engine room while engine is running, since thehigh currents in the Common Rail system produce considerable mag- netic fields.

6
VEHICLE MAINTENANCE REQUIREMENTS
13
G080E01P-GAT
o Vacuum and Crankcase
Ventilation Hoses
Inspect the surface of hoses for evi- dence of heat and/or mechanical dam- age. Hard and brittle rubber, cracking, tears, cuts, abrasions, and excessiveswelling indicate deterioration. Particu- lar attention should be paid to examin- ing those hose surfaces nearest tohigh heat sources, such as the ex- haust manifold. Inspect the hose routing to assure that the hoses do not come in contact with any heat source, sharp edges or mov- ing component which might cause heatdamage or mechanical wear. Inspect all hose connections, such as clamps and couplings, to make sure they aresecure, and that no leaks are present. Hoses should be replaced immedi- ately if there is any evidence of dete-rioration or damage. G080F01P-GAT
o Fuel Hose, Vapor Hose and
Fuel Filler Cap
The fuel hose, vapor hose and fuelfiller cap should be inspected at those intervals specified in the maintenance schedule. Make sure that a new fuelhose, vapor hose or fuel filler cap is correctly replaced. Consult your Hyundai dealer if you have any ques-tions. G080G01P-GAT
o Air Cleaner Filter
A genuine Hyundai part is recom- mended for replacement of the air cleaner filter. G080H01P-GAT
o Spark Plugs (Gasoline) Make sure to install new spark plugs of the correct heat range. G080I01P-GAT
o Drive Belts Inspect all drive belts (water pump and alternator) for evidence of cuts, cracks, excessive wear or oiliness, and re- place if necessary. Drive belts shouldbe checked periodically for proper ten- sion and adjusted as necessary. G080J01P-GAT
o Engine Coolant The coolant should be changed at those intervals specified in the Vehicle Maintenance Requirements Section. G080K01P-GAT
o Timing Belt Inspect all parts related with the timing belt for damage and deformation. Re-place any damaged parts.

6VEHICLE MAINTENANCE REQUIREMENTS
14
G080N01P-GAT
o Brake Hoses and Lines
Visually check for proper installation,
chafing, cracks, deterioration and any leakage. Replace any deteriorated or damaged parts immediately.
G080O01P-GAT
o Brake Fluid
Check brake fluid level in the brake
fluid reservoir. The level should be between "MIN" and "MAX" marks on the side of the reservoir. Use onlyhydraulic brake fluid conforming SAE J1703.
G080P01P-GAT
o Rear Brake Drums and
Linings
Check for scoring, burning, leaking
fluid, broken parts, and excessive wear. G080Q01P-GAT
o Brake Pads, Calipers and
Rotors
Check the pads for excessive wear, discs for run out and wear, and cali- pers for fluid leakage. G080R01P-GAT
o Parking Brake
Inspect the parking brake system such as parking brake lever, cables, and so on. For detailed service procedures,refer to the Shop Manual.
G080S01P-GAT
o Exhaust Pipe Connections,
Muffler and Suspension Bolts
Check the exhaust pipe, muffler, and
suspension connections for loosenessor damage.
G080L01P-GAT
o Manual Transmission Oil Check manual transmission oil ac- cording to the maintenance schedule. NOTE: If the oil level is low, check for possible leaks before adding oil. Do not overfill. G080M03P-GAT
o Automatic Transmission Fluid The fluid level should be in the "HOT" range of the dipstick, after engine and transmission are at normal operatingtemperature. Check the Automatic Transmission Fluid level with the en- gine running and the transmission inneutral, with the parking brake properly applied. Use MOBIL DEXRON-II or DIAMOND ATF SP-I when adding orchanging fluid.

6
VEHICLE MAINTENANCE REQUIREMENTS
15
G080T01P-GAT
o Steering Bear Box, Linkage
and Boots
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 dustboots and ball joints for deterioration, cracks, or damage. Replace any dam- aged parts. G080U01P-GAT
o Wheel Bearing Grease
Check the wheel bearings and grease according to the maintenance sched- ule. For inspection procedures, seeShop Manual.

7EMISSION CONTROL SYSTEM
2EMISSION CONTROL SYSTEM
H010A01P-GAT (Gasoline) Your Hyundai is equipped with an emission control system. There are three emission control sys- tems which are as follows.
(1) Crankcase emission control sys- tem
(2) Evaporative emission control sys- tem
(3) Exhaust emission control systemIn order to assure the proper function of the emission control systems, it is recommended that you have your vehicle inspected and maintained byan authorized Hyundai dealer in ac- cordance with the maintenance sched- ule in this manual. H020A01P-GAT
1. Crankcase Emission Control
System
The positive crankcase ventilation
system is employed to prevent airpollution caused by blow-by gases being emitted from the crankcase.This system supplies fresh air to the crankcase through the air cleaner. Inside the crankcase, the fresh airmixes with blow-by gases, then passes through the PCV valve into the induction system.
H080A01P-GAT PCV Valve The crankcase ventilation system must be kept clean to maintain good engine performance. Periodic servicing is required to re- move combustion products from the PCV valve. H030A01P-GAT
2. Evaporative Emission Control
System (except canister)
The Evaporative Emission ControlSystem is designed to prevent fuel vapors from escaping into the atmo-sphere.If the fuel-vapor vent line is cloggedor damaged, the fuel-vapor mixturewill escape into the atmosphere and cause insufficient emission control. Disconnect the line at both ends, and blow it clean with compressed air. Remove the filler cap from the filler pipe, and check to see if there is evidence that the packing contact to the filler pipe is faulty. The overfilllimiter (2-way valve) installed on the vapor line between the canister inlet and fuel tank outlet must be checkedfor correct operation.

7
EMISSION CONTROL SYSTEM
3CATALYTIC CONVERTER
H040A01P-GAT Canister While the engine is inoperative, fuel vapors generated inside the fuel tank are absorbed and stored in the canis-ter. When the engine is running, the fuel vapors absorbed in the canister are drawn into the induction systemthrough the purge control solenoid valve. H090A01P-GAT Purge Control Solenoid Valve The purge control solenoid valve is controlled by the ECU; when the en-gine coolant temperature is low, and during idling, it closes, so that evapo- rated fuel is not taken into the surgetank. After engine warm-up, during ordinary driving, it opens so as to introduce evaporated fuel to the surgetank. H050A01P-GAT
3. Exhaust Emission Control
System
The Exhaust Emission Control Sys-
tem is a highly effective system which controls exhaust emission while main-taining good vehicle performance. H060A01P-GAT All Hyundai vehicles are equipped with a monolith type three-way cata- lytic converter to reduce the carbonmonoxide, hydrocarbons and nitrogen oxides contained in the exhaust gas.
H010A01P
Catalytic converter