2004 Hyundai H-1 (Grand Starex) cooling

44IN CASE OF EMERGENCY
22IF THE ENGINE OVERHEATS
CAUTION:
o Do not allow the jumper cable clips to touch one another.
o Do not connect the jumper cable
to the negative terminal of the flat battery. The battery generates explosive gas, and a spark caused whenthe jumper cable is disconnected from the negative terminal could ignite this gas and cause an ex-plosion.
o Be careful that the jumper cable
becomes not caught in the cool-ing fan, etc.
! D030A02A-AAT If your temperature gauge indicates overheating, you experience a loss of power, or hear loud pinging or knock- ing and the engine is probably too hot.If this happens to you, you should:
1. Pull off the road and stop as soon as
it is safe to do so.
2. Place the gear selector lever in "P"
(automatic transmission), or neutral (manual transmission) and set the parking brake. If the air conditioning is on, turn it off.
3. If engine coolant is running out un- der the car or steam is coming outfrom the hood, stop the engine. Donot open the hood until the engine coolant has stopped running or the steaming has stopped. If there is novisible loss of engine coolant and no steam, leave the engine running and check to be sure the enginecooling fan is operating. If the fan is not running, turn the engine off.
the other end to the engine block of the vehicle with the flat batteryat the point farthest from the battery.
8. Start engine as described "Starting the engine" in section 3.
9. After the engine is started, discon- nect the cables in the reverse order.
1. Both batteries must be 12V. The
capacity (Ah) of the battery supply- ing current should not be signifi- cantly below that of the discharged battery.
2. Use only heavy-duty jumper cables.
3. A discharged battery can freeze. A
frozen battery must be thawed out before connecting the jumper cables.
4. There should be no contact be-
tween the two vehicles; otherwisecurrent may flow when the positive terminal is connected.
5. The discharged battery must be correctly connected to the vehicleelectrical system.
6. Run the engine of the vehicle sup- plying current.
7. Connect the jumper cables as fol-
lows:
(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 the booster battery.
(2) Connect one end of the other jumper cable to the negative ter-minal of the booster battery, and

4
CORROSION PREVENTION AND APPEARANCE CARE
23
4
IN CASE OF EMERGENCY
23
4. Check to see if the water pump drive belt is missing. If it is not missing, check to see that it is tight. If the drive belt seems to be satisfactory, check for engine coolant leakingfrom the radiator, hoses or under the car. (If the air conditioning had been in use, it is normal for coldwater to be draining from it when you stop).
!WARNING:
While the engine is running, keep hair, hands, long hair and clothing away from moving parts such as the fan and drive belts to preventinjury.
!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 andhigh pressure pipes are subject to high pressure even after the engine stopped. The fuel jet produced byfuel leaks may cause serious in- jury, if it touch the body. People using pacemakers should not movethan 30cm closer to the ECU or wiring harness within the engine room while engine is running, sincethe high currents in the Common Rail system produce considerable magnetic fields.
5. If the water pump drive belt is bro- ken or engine coolant is leaking out, stop the engine immediately and call the nearest Hyundai dealer for assistance.!WARNING:
Do not remove the radiator cap when the engine is hot. This can allow coolant to be blown out of the open- ing and cause serious burns.
6. If you cannot find the cause of the overheating, wait until the engine temperature has returned to nor-mal. Then, if the engine coolant has been lost, carefully add coolant to the reservoir (page 8-12) to bringthe fluid level in the reservoir up to the halfway mark.
7. Proceed with caution, keeping alert for further signs of overheating. Ifoverheating happens again, call a Hyundai dealer for assistance.
CAUTION:
Serious loss of engine coolant indi-cates there is a leak in the coolingsystem and this should be checked as soon as possible by a Hyundai dealer.
!

8DO-IT YOURSELF MAINTENANCE
10CHECKING THE ENGINE COOLANT
G350A01A-GAT ENGINE OIL CONSUMPTION Function of Engine Oil Engine oil has the primary function of lubricating and cooling the inside of the engine. Engine oil consumption It is normal that an engine should consume some engine oil while nor- mal driving. The cause of oil con- sumption in a normal engine are asfollows;
o Engine oil is used to lubricate pis-
tons, piston rings and cylinders. A thin film of oil is left on the cylinder wall when a piston moves downwards in the cylinder. High negative pressure generated dur-ing engine operation sucks some of the oil into the combustion cham- ber.This oil with some oil of the cylin-der wall is burned by the high tem-perature combustion gases during the combustion process. o The engine oil consumption is
strongly effected by the viscosity and quality of oil, engine rpm and driving condition etc. The engine oil is more consumed under severedriving conditions such as high speeds and frequent acceleration and deceleration than normal driv-ing condition. I080A02P-GAT
!WARNING:
Do not remove the radiator cap
when the engine is hot. When the engine is hot, the engine coolant is under pressure and may erupt through the opening if the cap isremoved. You could be seriously burned if you do not observe this precaution. Do not remove theradiator cap until the radiator is cool to the touch.
I080A01P

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A translucent coolant reservoir tank is
in the engine compartment.
The coolant level in this tank should
be kept between the "L" and "F" marks when measured while the engine iswarm and idling.
The cooling system is a closed sys-
tem and normally the loss of coolant should be very slight. A noticeable drop in the coolant level could indi-cate leakage. If this occurs, have the system
checked at an authorized HYUNDAIdealer as soon as possible. If the level should drop below the "L"
level on the reservoir tank, add cool- ant.
Also, if the reservoir tank is com-
pletely empty, remove the radiatorcap and add coolant until the level reaches the filler neck.
!WARNING:
Do not open the reservoir tank lid
or radiator cap while the engine is hot. The coolant system is under pressure and any hot coolant es-caping could cause severe burns. G050B01A-AAT Recommended Engine Coolant Use a high quality ethylene-glycol coolant in a 50/50 mix with water. The engine coolant should be compatible with aluminum engine parts. Addi-tional corrosion inhibitors or additives should not be used. The cooling sys- tem must be maintained with the cor-rect concentration and type of engine coolant to prevent freezing and corro- sion. Never allow the concentration ofantifreeze to exceed the 60% level or go below the 35% level, or damage to the cooling system may result. Forproper concentration when adding or replacing the engine coolant, refer to the following table.
Water
65% 60%50%40%
35%40%50%60%
Ambient
temperature °C ( °F)-15 (5)
-25 (-13) -35 (-31)-45 (-49) Engine coolant concentration
Antifreezesolution G050C01A-GAT To Check the Coolant Level The coolant level can be seen on the side of the plastic coolant reservoir. The level of the coolant should be between the "L" and "F" lines on thereservoir when the engine is cold. If the level is below the "L" mark, add engine coolant to bring it up between"L" and "F". If the level is low, inspect for coolant leaks and recheck the fluid level frequently. If the level dropsagain, visit your Hyundai dealer for an inspection and diagnosis of the rea- son.

8DO-IT YOURSELF MAINTENANCE
12
!
4. Turn the radiator cap counterclock-
wise without pressing down on it, until it stops. This relieves any pres- sure remaining in the cooling sys- tem. And remove the radiator capby pushing down and turning coun- terclockwise. Now fill the radiator with clean dem- ineralized or distilled water. Con- tinue to add clean demineralized or distilled water in small quantitiesuntil the fluid level stays up in the radiator neck.
5. Start the engine, top off the radia- tor with water and then add engine coolant to the reservoir until thelevel is between "L" and "F".
6. Replace the radiator and reservoir caps and check to be sure thedrain cocks are fully closed and not leaking. WARNING:
The cooling fan is controlled by
engine coolant temperature andmay sometimes operate even when the engine is not running. Useextreme caution when working near the blades of the cooling fan so that you are not injured by a rotat-ing fan blade. As the engine cool- ant temperature decreases, the fan will automatically shut off. This isa normal condition.
G050D02P-AAT To Change the Coolant The coolant should be changed at those intervals specified in the ve- hicle maintenance schedule in Sec- tion 6.
!
CAUTION:
Engine coolant can damage the finish of your car. If you spill en-gine coolant on the car, wash it off thoroughly with clean water.
1. Park the car on level ground, set the parking brake and remove the radiator cap when cool.
2. Be sure your drain receptacle is in
place. Open the drain cock on theradiator. Allow all the engine cool- ant to drain from the cooling sys- tem, then securely close the draincock.
3. Check Section 9 for the capacity of the cooling system in your car.Then, following the manufacturer's directions on the engine coolant container, add the appropriatequantity of coolant to the radiator.

8DO-IT YOURSELF MAINTENANCE
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o The battery electrolyte is ex-tremely caustic. Do not allow it to come in contact with youreyes, skin, clothing, or the painted surfaces of the vehicle. Spilled electrolyte should be flushed immediately with ample amounts of water. Irritation to eyes or skin from contact withelectrolyte requires immediate medical attention.
o If the battery is to be quick- charged, first disconnect the battery cables.
o In order to prevent a short cir- cuit, be sure to disconnect thenegative (-) terminal before do- ing anything else.AIR CONDITIONING CARE
G140A01A-AAT Keeping the Condenser Clean The air conditioning condenser (and engine radiator) should be checked periodically for accumulation of dirt, dead insects, leaves, etc. These caninterfere with maximum cooling effi- ciency. When removing such accu- mulations, brush or hose them awaycarefully to avoid bending the cooling fans.
G140B01A-AAT Checking the Air Conditioning Operation
1. Start the engine and let it run at a fast idle for several minutes with the air conditioning set at the maxi-mum cold setting.
2. If the air coming out of the in-dash
vents is not cold, have the air con-ditioning system inspected by your Hyundai dealer. G140C01A-AAT Lubrication To lubricate the compressor and the seals in the system, the air condition- ing should be run for at least 10 minutes each week. This is particu-larly important during cool weather when the air conditioning system is not otherwise in use.CAUTION:
Running the air conditioning sys- tem for extended periods of time with a low refrigerant level maydamage the compressor.
!

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!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

10
INDEX
3
D
DAY/NIGHT INSIDE REARVIEW MI RROR .............2-34
DEFROSTING/DEFOGGING ...................................2-43
DIGITAL CLOCK ...................................................... 2-37
DOOR LOCKS .......................................................... 1-12
DRINK HOLDER ....................................................... 2-35
DRIVING FOR ECONOMY ......................................3-25
DRIVING WITH ELECTRONIC DUAL-RANGE AUTOMATIC TRANSM ISSION ............................. 3-13
EEMISSION CONTROL SYSTEM ............................... 7-2
ENGINE ...................................................................... 9-3
ENGINE COMPARTMENT ......................... ................ 8-2
ENGINE COOLANT .................................................. 8-10
ENGINE COOLANT TEM PERATURE GAUGE.......2-12
ENGINE NUMBER ..................................................... 1-5
ENGINE OI L ............................................................... 8-7
ENGINE RPM ADJUSTMENT KNOB ......................2-24
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS .............. ...........................6-12
FFOUR-WHEEL DRIVE (4WD) ..................................3-15
FRONT DOOR EDGE WARNING LIGHT ...............2-25
FRONT DOOR WINDOW GLASS ...........................1-25
FRONT FOG LIGHT SWITCH .................................2-25FRONT/REAR WINDOW DEFROSTER
SWITCH .. 2-26
FUEL GAUGE ........................................................... 2-12
FUEL TANK CAPACITY ............................................. 9-2
FUSE PANEL DESCRIPTION ..................................4-37
GGENERAL CHECKS ................................................... 8-6
GOOD BRAKING PRACTICE ..................................3-22
HHAZARD WARNING SYSTEM................................ 2-26
HEADLIGHT AIMING ADJUSTMENT ......................4-26
HEADLIGHT LEVELING DEVICE SYSTEM ............2-23
HEADREST ............................................................... 1-35
HEATING AND COOLING CONTROL ....................2-38
HEATING CONTROLS ............................................. 2-42
HEIGHT ADJUSTABLE FRONT SEAT SHOULDER BELT ...................................................................... 1-38
HIGH-MOUNTED REAR STOP LIGHT ...................2-25
HOLD OPEN LOCK SYSTEM................................. 1-13
HOOD RELEASE ..................................................... 1-23
HORN ........................................................................ 2-37