2004 Hyundai H-1 (Grand Starex) belt

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

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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.

Engine Compartment ................................................... 8-2
General Checks ........................................................... 8-6
Checking the Engine Oil .............................................. 8-7
Checking the Engine Coolant ...................................8-10
Checking the Battery ................................................. 8-13
Air Conditioning Care ................................................ 8-14
Changing the Air Conditioner Filter .......................... 8-15
Checking the Brake Fluid .......................................... 8-16
Checking the Clutch Fluid ......................................... 8-17
Checking the Automatic Transmission Fluid ............ 8-17
Filling the Washer Reservoir ..................................... 8-19
Windshield Wiper Blades ........................................... 8-20
Tail Gate Window Washer Fluid ............................... 8-21
Checking the Freeplay ............................................... 8-21
Checking Drive Belts ................................................. 8-22
Tire ............................................................................. 8-23
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DO-IT YOURSELF MAINTENANCE
8

8DO-IT YOURSELF MAINTENANCE
6GENERAL CHECKS
I020A03P-GAT Engine Compartment The following should be checked regu- larly:
o Engine oil level and condition
o Transmission fluid level and condi- tion
o Brake fluid level
o Clutch fluid level
o Engine coolant level
o Windshield washer fluid level
o Accessory drive belt condition
o Coolant hose condition
o Fluid leaks
(on or below components)
o Power steering fluid level and con-
dition
o Battery condition
o Air filter condition I030A03P-GAT Vehicle Exterior The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut tight-
ness
o Air cleaner filter condition
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and corrosion
o Fluid leaks
o Door and hood lock condition
o Tire pressure and condition
(including spare) I040A01P-GAT Vehicle Interior The following should be checked each time when the vehicle is driven:
o Light operation
o Windshield wiper operation
o Horn operation
o Defroster, heater operation
(and air conditioning, if equipped)
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, in-
cluding clutch operation
o Automatic transmission operation,
including "Park" mechanism opera-tion
o Seat control condition and opera-
tion
o Seat belt condition and operation
o Sunvisor operation

8
DO-IT YOURSELF MAINTENANCE
7CHECKING THE ENGINE OIL
If you notice anything that does not
operate correctly or appear to be func- tioning correctly, inspect it carefully and seek assistance from your Hyundai dealer if service is needed.
Adequate care of your vehicle at regu-
lar intervals serves to preserve thevalue and appearance as long aspossible.
Some maintenance items can be car-
ried out by the owner (Consumer Information), while other should be done only by an authorized dealer(Periodic Inspection and Mainte- nance). This section describes only those items which can be carried outby the owner. In the event a malfunc- tion or other problem is discovered, have it corrected by an authorizedHYUNDAI dealer. This section con- tains information on inspection main- tenance procedures that you can doyourself, if you so desire. Follow the instructions and cautions for each of the various procedures. When checking or servicing the in-side of the engine compartment, besure the engine is stopped and has had a chance to cool down. If it is necessary to do work in the enginecompartment with the engine running, be especially careful that your cloth- ing, hair, etc., becomes not caught bythe fan, V-belts, or other moving parts.
I070A06P-GAT Recommended Oil Diesel Engine
(1) Select engine oil of the proper
SAE viscosity number according to the atmospheric temperature. Recommended viscosity is given in the following illustration.
2.5 CRDi only
I070A06P

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DO-IT YOURSELF MAINTENANCE
15
G140D01HP-GAT
Checking the Compressor Drive Belt When the air conditioning is being used regularly, the compressor drivebelt tension should be checked at least once a month. To check the drive belt tension, press down on the belt halfway between the engine crankshaft and compressorpulleys. Pressing with your finger, you should not be able to deflect this belt anymore than 8.0 mm. If you havethe instruments to check it with a force of 98N (22 lb.), the deflection should be approx. 8.0 mm (0.315 in.).If the belt is too loose, have it ad- justed by your Hyundai dealer. NOTE: The compressor drive belt tension for diesel engine (2.5 CRDi only) isadjusted automatically.
HSM396-1
Gasoline
CHANGING THE AIR CONDITIONER FILTER
B140E01P
B140E01P-AAT (For Evaporator and Blower Unit) (If installed) The air conditioner filter is located in the air intake duct behind the wind- shield washer reservoir. It helps to decrease pollutants from entering the car.
1. Open the engine hood.
Auto tensionerpulley
COMP. pulley
Engine pulley
Generator pulley
G190D01P
Diesel (2.5 TCI)
Crankshaft pulley
COMP.pulley
Tension pulley
COMP. pulley
Autotensioner Crankshaftpulley
Diesel (2.5 CRDi)

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

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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.