2004 Hyundai H-1 (Grand Starex) engine

8
DO-IT YOURSELF MAINTENANCE
19
!WARNING:
The cooling fan is controlled by
engine coolant temperature and may sometimes operate even whenthe engine is not running. Use extreme caution when working near the blades of the cooling fan, sothat you are not injured by a rotat- ing fan blade. As the engine cool- ant temperature decreases, the fanwill automatically shut off. This is a normal condition.
FILLING THE WASHER RESERVOIR
I130A01P-GAT The washer fluid reservoir supplies
fluid to the windshield washer sys- tem.
A good quality washer fluid should be
used to fill the washer reservoir. Thefluid level should be checked more frequently during bad weather or whenever the washer system is inmore frequent use.
!WARNING (Diesel only):
Never work on injection system with engine running or within 30 seconds after shutting off engine.High pressure pump, rail, injec- tors and high pressure pipes are subject to high pressure even af-ter the engine stopped. The fuel jet produced by fuel leaks may cause serious injury, if it touch the body.People using pacemakers should not move than 30cm closer to the ECU or wiring harness within theengine room while engine is run- ning, since the high currents in the Common Rail system produceconsiderable magnetic fields. I130A01P

8DO-IT YOURSELF MAINTENANCE
20WINDSHIELD WIPER BLADES
NOTE:
o Do not operate the wipers on dry glass. This can result in more rapid wear of the wiper blades and may scratch the glass.
o Keep the blade rubber out of contact with petroleum productssuch as engine oil, gasoline, etc.
G080A02A-AAT The wiper blades should be carefully
inspected from time to time and cleaned to remove accumulations ofroad film or other debris. To clean the wiper blades and arms, use a clean sponge or cloth with a mild soap ordetergent and water. If the wipers continue to streak or smear the glass, replace them with genuine Hyundaireplacement parts or their equivalent. HEF119
CAUTION:
o Radiator antifreeze (engine cool- ant) should not be used in thewasher system because it will damage the car’s finish.
o The washer lever should not be pulled and the washer should not be operated if the washerreservoir is empty. This can dam- age the washer fluid pump.
!

8
DO-IT YOURSELF MAINTENANCE
21TAIL GATE WINDOW WASHER FLUID
I140A02P-GAT (Minibus/Van) (If installed) After opening the cover of quarter trim panel which is located on the left side of quarter trim, check the fluid level. If the fluid level is low, refill thewasher fluid. HSRFL140CHECKING THE FREEPLAY
G150A01A-GAT Steering Wheel To check the steering wheel freeplay, stop the car with the wheels pointed straight ahead and gently move the steering wheel back and forth. Usevery light finger pressure and be sen- sitive to changes in resistance that mark the limits of the freeplay. If thefreeplay is greater than specified, have it inspected by your Hyundai dealer and adjusted or repaired if necessary. 30 mm (1.18 in.)
G160A01A-GAT Clutch Pedal With the engine off, press lightly on the clutch pedal until you feel a change in resistance. This is the clutch pedal freeplay. The freeplay should be withinthe limits specified in the illustration. If it is not, have it inspected by your Hyundai dealer and adjusted or re-paired if necessary. 6 ~ 13 mm (0.24 ~ 0.51 in.)
HSROM109 G160A01E

8DO-IT YOURSELF MAINTENANCE
22CHECKING DRIVE BELTS
G180A01A-GAT CHECKING BRAKE PEDAL CLEARANCE
G180A01L
45.1 mm (1.78 in.)
You need a helper to check the brake pedal clearance. With the engine run- ning, have your helper press down on the brake pedal several times andthen hold it down with a force of about 490N (50 kg, 110 lbs). The brake pedal clearance is the distance fromthe top surface of the brake pedal to the asphalt sheeting under the floor mat. If the brake pedal clearance isnot within the limits specified in the illustration, have it inspected by your Hyundai dealer and adjusted or re-paired if necessary.
G170A01A-GAT Brake Pedal With the engine off, press down on the brake pedal several times to re-duce the vacuum in the brake booster.Then, using your hand, press downslowly on the brake pedal until you feel a change in resistance. This is the brake pedal freeplay. The freeplayshould be within the limits specified in the illustration. If it is not, have it inspected by your Hyundai dealer andadjusted or repaired if necessary.
3 ~ 8 mm (0.12 ~ 0.31 in.)
G160A01E G190A01P-GAT
G190D01P-1
Diesel (2.5 CRDi)
Diesel (2.5 TCI)
HSM396-1
Gasoline
Auto tensioner pulley COMP.pulley
Engine pulley
Power steering pulley
Generator pulley
Generator pulley Crankshaftpulley
COMP.pulley
Tensionpulley
Water pump pulley
Power steering pulley
Generator pulley
Idler pulleyWater pump pulley
Idler pulley COMP.pulley
Powersteeringpulley Autotensioner
Crankshaft pulley Idler pulley

8
DO-IT YOURSELF MAINTENANCE
23
I230A01P-GAT PARKING BRAKE LEVER STROKE Pull the parking brake lever all the way up to check the number of "clicks" that the ratchet makes. One click represents a lever movement of onenotch. The lever should move the specified number of notches for nor- mal brake application. Parking brake lever stroke; If the parking brake lever stroke is not within the standard range(5 to 7 notches), have the brake lever ad-justed at an authorized HYUNDAI dealer. D030A01P
TIRE
I150A02P-GAT Tire condition Check the tires for cuts, cracks and other damage. Replace the tires if there are deep cuts or cracks. Also check each tire for pieces of metal orpebbles.The use of worn tires can be verydangerous because of the greater chance of skidding or hydroplaning. The tread depth of the tires mustexceed 1.6 mm (0.06 in.) in order for the tires to meet the minimum re- quirement for use. If there are belt-line wear indicators on the tires, they will appear in six places on the surface of the tirethereby indicating that the tire no 1.6 mm (0.06 in.)
I090A01A
Wear indicator
Drive belts should be checked peri-
odically for proper tension and ad-justed if necessary. At the same time, belts should be examined for cracks, wear, fraying or other evidence ofdeterioration and replaced if neces- sary.
Belt routing should also be checked
to be sure there is no interferencebetween the belts and other parts of the engine. After a belt is replaced,the new belt should be adjusted again after two or three weeks to eliminate slack resulting from initial stretchingafter use.
NOTE: The drive belt tension for diesel
engine (2.5 CRDi only) is adjusted automatically.

Measurement................................................................ 9-2
Engine ........................................................................... 9-3
Lubrication Chart .......................................................... 9-4
9
VEHICLE SPECIFICATIONS
9

9
VEHICLE SPECIFICATIONS
3ENGINE
J040A05P-GAT J050A04P-GAT ELECTRICAL D4BH(TCI)

20.5
Elec.:ATDC 9°±1°
Mech.:ATDC 7°±1° (A tropical region)
Mech.:ATDC 9°±1°
(Except a tropical region) 750 ± 100
ITEMS Engine typeTotal displacement Compression ratio Firing order Injection (or Ignition) timingIdle speed (RPM) D4BB(N/A)
2,607 cc
22
1 - 3 - 4 - 2
ATDC 5°
850 ± 100DIESEL
GASOLINE (Minibus/Van) 12V-68AH MF
13.5V-110A12V-1.2 kw
* FOR USE ONLY IN COLD AREA
GASOLINE G4JS
2,351 cc 10

BTDC 8°± 5°
750 ± 100
D4CB(TCI)
2,497 cc
17.6
-
800 ± 100
ITEMS Battery Generator Starter DIESEL
12V-90AH MF, 100AH MF*
12V- 2.2kw
2.5 CRDi 4D56 TCI(With A/CON) 4D56 TCI(Without A/CON) 12V-110A 12V-110A
12V-75A

9 VEHICLE SPECIFICATIONS
4LUBRCATION CHART
J060A07P-GAT OIL & GREASE STANDARDSAE 30 (ABOVE 0°C) SAE 20W-40 (ABOVE -10°C)SAE 15W-40 (ABOVE -15°C)SAE 10W-30 (-20°C ~ 40°C)SAE 5W-30 (-25°C ~ 10°C)SAE 0W-30 (BELOW 10°C) *1SAE 30 (0°C ~ 40°C)SAE 20W-40 (ABOVE -10°C)SAE 15W-40 (ABOVE -15°C)SAE 10W-30 (-20°C~ 40°C)SAE 5W-30 (-25°C~ 10°C)SAE 0W-30 (BELOW 10°C) *1SAE 20W-40, 20W-50 (ABOVE -10°C)SAE 15W-40, 15W-50 (ABOVE -15°C)SAE 10W-30 (-25°C ~ 40°C)SAE 10W-40, 10W-50 (ABOVE -25°C)SAE 5W-20 (BELOW -10°C) *1, *2SAE 5W-30 (BELOW 10°C) *1SAE 5W-40 (BELOW 20°C) *1
NORMAL DRIVING CONDITIONSEVERE DRIVING CONDITION
ITEMS
ENGINE OIL (DIESEL) ENGINE OIL (GASOLINE) ENGINE OIL CONSUMPTIONQUANTITY (LITER)
Engine Oil : 6.1 at Oil Pan : 4.9
Engine Oil : 7.4 at Oil Pan : 6.6 (MAX) 4.9 (MIN)
Engine Oil : 4.3 at Oil Pan : 4.0 (MAX) 3.0 (MIN)
at Oil Filter : 0.3
Max. 1L/ 1,500 km Max. 1L/ 1,000 km
API CF-4 or ABOVE API CF-4 or ABOVE API CF-4 or ABOVE API SG, SG/CD, SH or SH/CD API SE or ABOVE
2.6 N/A2.5 4D56 TCI 2.5 CRDi TCIE.C Except E.C
*1. Restricted by driving condition and area.
*2. SAE 5W-20 not recommended for sustained high speed vehicle operation.