2004 Hyundai H-1 (Grand Starex) water pump

2
INSTRUMENTS AND CONTROLS
13
C090C02P
!WARNING:
Never remove the radiator cap when the engine is hot. The engine cool- ant is under pressure and could erupt and cause severe burns. Waituntil the engine is cool before re- moving the radiator cap. The needle on the engine coolant tem- perature gauge should stay in the nor-mal range. If it moves across the dial to "H" (Hot), pull over and stop as soon as possible and turn off the engine. Thenopen the hood and after the engine has cooled, check the coolant level and the water pump drive belt. If you suspectcooling system trouble, have your cool- ing system checked by a Hyundai dealer as soon as possible. C040A02P-GAT SPEEDOMETER Minibus/Van
The speedometer indicates the vehicle's speed in kilometers per hour(km/h) or miles per hour (mph).
C040A02P C040A01P-1
Truck
Truck

4
CORROSION PREVENTION AND APPEARANCE CARE
19
4
IN CASE OF EMERGENCY
19
2. Pump the hand pump until there are
no more bubbles in the fuel coming out of the air plug. When doing this,place a cloth around the air plug to prevent the escaping fuel from spew- ing about.
3. Tighten the air plug when there are no more bubbles in the fuel.
4. Continue pumping until the hand pump becomes stiff.
5. Finally, check to be sure that there
is no leakage of fuel.If in doubt, consult your nearest authorized HYUNDAI dealer. E090A02P
REMOVAL OF WATER FROM THE FUEL FILTER
E100A02P-GAT If the fuel filter warning lamp illumi- nates during driving, it indicates thatwater has accumulated in the fuel fil- ter. If this occurs, remove the water as described below.
1. Loosen the drain plug at the bottom
of the fuel filter.
Drain plug
!WARNING:
o Do not smoke or have any other open flame near the vehicle while bleeding the fuel system.
o Be sure to carefully clean away
any fuel which spilled ontonearby parts coming out of the air plug, because such accumu- lations of fuel might ignite andcause a fire. GS40310A

44IN CASE OF EMERGENCY
20IF THE ENGINE WILL NOT START
!WARNING:
o Do not smoke or have any other open flame near the vehicle while bleeding the fuel system.
o Be sure to carefully wipe away
any water drained out in thismanner, because the fuel mixed in the water might be ignited and result in a fire.
NOTE: It is recommended that water accu- mulated in the fuel filter should be removed by an authorized Hyundaidealer.
!
D010A01A-AAT
WARNING:
If the engine will not start, do not push or pull the car to start it. This could result in a collision or causeother damage. In addition, push or pull starting may cause the cata- lytic converter to be overloaded andcreate a fire hazard.
2. Operate the hand pump slowly 6 or 7 times in order to force the waterout through the drain plug.
3. Tighten the drain plug when water no longer comes out.
4. Loosen the air plug and bleed the air. (Refer to "Bleeding the fuel sys- tem".)
5. Check to be sure that the warning lamp illuminates when the ignitionkey is turned to "ON", and that itgoes off when the engine is started. If in doubt, consult your nearest authorized HYUNDAI dealer. Pump
GS40320A

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.
!

6VEHICLE MAINTENANCE REQUIREMENTS
4
KILOMETERS X 1000 MONTHS
NO.1 2 3 4 5 6 7 8 DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (GASOLINE)ENGINE OIL AND FILTER AIR CLEANER FILTER FUEL FILTER FUEL SYSTEM LEAKS SPARK PLUGS VACUUM CRANKCASE VENTILATION HOSE TIMING BELT DRIVE BELT (FOR WATER PUMP AND ALTERNATOR)
G010A02P-GAT EXCEPT EUROPEAN COMMUNITY The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for all vehicle services to protect your warranty. Where both kilometers and time are shown, the frequency of service is determined by whichever occurs first. R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary80 64
I I I I 90 72
R R I
R I
70 56
I I I
60 48
R R I I I I
50 40
I I I
40 32
I I I I
30
24
R R I I
20 16
I I I I
SCHEDULED MAINTENANCE
108
I I I
5 4
See Note (1)
Unleaded LeadedSee Note (2) See Note (3)
Note: (1) For every 15, 000 KM or 12 months, whichever occurs first "R"
(2) For every 100,000 KM : "R"
(3) For every 40,000 KM : "R"

6
VEHICLE MAINTENANCE REQUIREMENTS
5
NO. 1 2 3 4 5 6 7 8 9
1011 12 KILOMETERS X 1000 MONTHS
DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL) ENGINE OIL AND FILTER AIR CLEANER FILTER FUEL FILTER VALVE CLEARANCE INJECTION TIMING (IF EXHAUST GAS INCLUDES BLACK SMOKE) EGR SYSTEM (VALVE, TUBE, HOSE) TIMING BELT DRIVE BELT (FOR WATER PUMP AND ALTERNATOR) ENGINE IDLE SPEED FUEL SYSTEM LEAKS INJECTION NOZZLE (IF EXHAUST GAS INCLUDES BLACK SMOKE) VACUUM PUMP (WITH ALTERNATOR)
G020A04P-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
80 64
I I
R I I I I 90 72
RR I I II I
7056
I I I
60 48
RR II I I I I I I
50 40
I I I
40 32
I I I I I I I
30 24
RR I I II I
2016
I I I I I I108
I I I
5 4
I
See Note(1)
Note : (1) For every 5,000 KM or 6 months, whichever occurs first : "R" Republic of South Africa (If the vehicle is lubricated API CH-4 grade or above.) For every 7,500 KM or 6 months, whichever occurs first : "R"

6
VEHICLE MAINTENANCE REQUIREMENTS
7
NO. 1 2 3 4 5 6 7 DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (GASOLINE)
ENGINE OIL AND FILTER (SG OR ABOVE) See Note (1) AIR CLEANER FILTER FUEL FILTER FUEL SYSTEM LEAKS SPARK PLUGTIMING BELT DRIVE BELT (FOR WATER PUMP/ALTERNATOR)
75 60
R I I 90 72
R R R I
R I
6048
R R I I I
4536
R I
R
I
3024
R R I I
15 12
R I I
7.5
6
KILOMETERS X 1000 MONTHS
G040A03P-GAT
FOR EUROPEAN COMMUNITY ONLY
The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for
all vehicle services to protect your warranty. Where both kilometers and time are shown, the frequency of service is determined by whichever occurs first. R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
Note : (1) SF or LOWER : For every 10,000 KM or 6 months, whichever occurs first : "R" (2) For every 100,000 KM : "R"
See Note (2)

6VEHICLE MAINTENANCE REQUIREMENTS
8
NO.1 2 3 4 5 6 7 8 9
1011 12 DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (EXCEPT 2.5 CRDi DIESEL) ENGINE OIL AND FILTER AIR CLEANER FILTER FUEL SYSTEM LEAKS FUEL FILTER VALVE CLEARANCE EGR SYSTEM (VALVE, TUBE, HOSE) INJECTION TIMING (IF EXHAUST GAS INCLUDES BLACK SMOKE) TIMING BELT DRIVE BELT (FOR WATER PUMP/ALTERNATOR) ENGINE IDLE SPEED INJECTION NOZZLE (IF EXHAUST GAS INCLUDES BLACK SMOKE) VACCUM PUMP (WITH ALTERNATOR)
75 60
I I I 90 72
R I
R
II
R
I I I
6048
R I
R
II I I I I
4536
I I I
30 24
R I
R
II I I I
1512
I I I
7.5
6
KILOMETERS X 1000 MONTHS
G050A04P-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
See Note (2) See Note (3)
Note : (1) For every 7,500 KM or 6 months, whichever occurs first : "R" (2) For every 20,000 KM : "I"
(3) For every 20,000 KM or 16 months, whichever occurs first : "I" See Note (1)