2004 Hyundai Terracan engine overheat

DRIVING YOUR HYUNDAI 2- 19
CAUTION: If overheating should occur when towing,
(temperature gauge reads near red zone), taking the following action may reduce oreliminate the problem.
1. Turn off the air conditioner.
2. Reduce highway speed.
3. Select a lower gear when going uphill.
4. Whilst in stop and go traffic, place the gear selector in park or neutral and idle the engine at a higher speed.
HPC200E1-E
Trailer or Vehicle Towing Tips
1. Before towing, check towbar and safety cable connections as well as proper operation of the trailer running lights, brake lights, andturn signals.
2. Always drive your vehicle at a moderate speed (Less than 60 mph)
3. Trailer towing requires more fuel than nor- mal conditions.
4. To maintain engine braking efficiency and electrical charging performance, do not usefifth gear (manual transmission).
5. Always secure items in the trailer to prevent load shift whilst driving.
6. Check the condition and air pressure of all tyres on the trailer and your car. Low tyrepressure can seriously affect the handling.Also check the spare tyre.
7. The vehicle/trailer combination is more af- fected by crosswind and buffeting. When being passed by a large vehicle, keep a constant speed and steer straight ahead.If there is too much wind buffeting slowdown to get out of the other vehicle's airturbulence.
8. When parking your car and trailer, especial- ly on a hill, be sure to follow all the normalprecautions. Turn your front wheel into thecurb, set the parking brake firmly, and putthe transmission in 1st or Reverse (manual)or Park (automatic). In addition, place wheelchocks at each of the trailer's tyres. 9. If the trailer has electric brakes, start your
vehicle and trailer moving, and then applythe trailer brake controller by hand to besure the brakes are working. This lets youcheck your electrical connection at the sametime.
10. During your trip, check occasionally to be sure that the load is secure, and that thelights and any trailer brakes are still working.
11. Avoid jerky starts, sudden acceleration or sudden stops.
12. Avoid sharp turns and rapid lane changes.
13. Avoid holding the brake pedal down too long or too frequently. This could cause the brakes to overheat, resulting in reduced brakingefficiency.
14. When going down a hill, shift into a lower gear and use the engine braking effect. When ascending a long grade, downshift the transmission to a lower gear and reducespeed to reduce chances of engine over-loading and/or overheating.
15. If you have to stop whilst going uphill, do not hold the vehicle in place by pressing on theaccelerator. This can cause the automatictransmission to overheat. Use the parkingbrake or footbrake.
NOTE: When towing, check transmission fluid more
frequently.

IN CASE OF EMERGENCY
3-2
CAUTION:
Personal injury and damage to the vehicle
may occur if jump starting is not performed correctly. If any doubt exists as to how thisoperation should be performed, seek assis-tance from qualified personnel. WARNING:
Motor vehicle batteries contain sulphuric
acid and emit hydrogen gas. Protective cloth- ing should be worn and care exercised toprevent the acid from coming into contactwith skin or clothing and the vehicle. Nakedlights should not be permitted in the vicinityof the battery. Care should be exercised toprevent sparks occurring during connec-tion. If acid accidentally comes into contactwith skin or eyes, the affected area shouldimmediately be flushed with copious CAUTION: If the jump cable is incorrectly installed, damage to the vehicle electrical system mayoccur, in particular the electronic compo-nents such as the Fuel Injection system
computer and the Automatic Transmissioncomputer. The battery must never be dis-connected whilst the engine is running.
SD030A1-E JUMP STARTING
amounts of water and medical assistance sought.
1. Ensure that the booster battery is 12 volt type. If the booster battery is installed inanother vehicle, ensure that the two vehi-cles are not touching.
2. Turn off all unnecessary electrical equip- ment in both vehicles.
3. Ensure that the engine of the vehicle provid- ing the jump start is running prior to connec-tion of the jump cables.
4. Connect the red jump cable to the positive (+) terminal of the booster battery and theother end to the positive (+) terminal of thedis-charged battery.
5. Attach the black jump cable to the negative (-) terminal of the booster battery, and theother end to a ground point within the enginecompartment of the vehicle with the flat bat-tery. Do not connect to the negative batteryterminal of the flat battery since sparks maybe generated with the subsequent risk ofexplosion.
6. Raise the booster vehicle engine speed to 2,000 r.p.m. and start the engine of thevehicle with the flat battery.
7. Switch "ON" the main beam headlamps before carefully removing the jumper cablesin the reverse order of attachment. Oncethe jumper cables have been removed,switch "OFF" the main beam headlamps. HPD040A2-E IF THE ENGINE OVERHEATS If the temperature gauge indicates overheating:
1. Pull off the road and stop as soon as it is
safe to do so.
2. Place the gear selector lever in "P" (auto- matic), or neutral (manual transmission) and set the parking brake. If the air conditioningis on, turn it off.
3. If coolant is running out under the car or steam is coming out from under the bonnetstop the engine. Do not open the bonnetuntil the coolant has stopped running or thesteaming has stopped. If there is no visibleloss of coolant and no steam, leave theengine running and check to be sure theengine cooling fan is operating. If the fan is not running, turn the engine off.
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 besatisfactory, check for coolant leaking fromthe radiator, hoses or under the car. (If theair conditioning had been in use, it is normalfor cold water to be draining from it).
AX30030A
Negative to the engine not to the battery
Positive to positive
Booster battery
c
e
f d
Discharged battery

IN CASE OF EMERGENCY 3-3
WARNING: Whilst the engine is running, keep hands
and clothing away from moving parts such as the fan and drive belts to prevent injury.
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 tohigh pressure even after the engine stopped.The fuel jet produced by fuel leaks maycause serious injury, if it touch the body.People using pacemakers should not movethan 30cm closer to the ECU or wiring har-ness within the engine room while engine isrunning, since the high currents in the Com-mon Rail system produce considerable mag-netic fields.
5. If the water pump drive belt is broken or coolant is leaking out, stop the engine imme- diately and call the nearest Hyundai dealerfor assistance.
WARNING: Do not remove the radiator cap when the
engine is hot since steam and boiling water may be ejected from the radiator resulting inburns or scalding. YD050A1-E
SPARE TYRE For Full Size
The following instructions for the FULL SIZE
spare tyre should be observed:
Check inflation pressure as soon as possible
after installing the spare tyre, and adjust to the specified pressure. The tyre pressure shouldbe periodically checked and maintained at thespecified pressure whilst the tyre is stored.
Spare Tyre Pressure
Inflation Pressure
Tyre Size
FULL SIZE 29 psi (200 kPa)
6. If the cause of the overheating cannot be
found, wait until the engine temperature has returned to normal. Then, if coolant hasbeen lost, carefully remove the radiator capand add water to bring the fluid level in thereservoir up to the base of the radiator fillopening. Fill the coolant expansion tank tothe halfway mark.
7. Proceed with caution until it is established that the engine is operating normally. If theengine overheats repeatedly, the advice of aHyundai dealer should be sought.
CAUTION: Serious loss of coolant indicates there is a
leak in the cooling system and this should be checked as soon as possible by a Hyundaidealer.
D040B01HP
D040B03HP-EAT
Handling the Spare Tyre
1. Obtain the spare wheel rod (Jack handle) after folding up the seat cushion of the rear seat . To fold up the seat cushion, refer to the page 1-15.
D060B01HPB090B02HP
Rear seat

OWNER MAINTENANCE
6-6
To replace the oil and filter, proceed as follows:
1. Ensure that the engine is at normal operat- ing temperature and park the vehicle on level ground with the parking brake securelyapplied and the engine turned off.
2. Open the bonnet and remove the oil filler cap.
3. Prepare a suitable receptacle to collect the displaced oil and remove the drain plug fromthe sump.
CAUTION: The oil being drained from the engine will be
hot. Care should be exercised to prevent scalding.
4. When the oil has drained from the sump, replace the drain plug using a new washer ensuring that the plug is not over tightened. Tightening torque is: 3.5 ~ 4.5 kgf.m
5. Remove the oil filter by rotating counter- clockwise, using a proprietary oil filter re- moval tool if necessary. Note that the oilfilter will contain approximately 0.5 litres ofoil and this should be collected in a suitablereceptacle.
6. Install a new oil filter having smeared the sealing ring with clean oil and rotating clock-wise until the filter contacts the mountingand then a further one half turn. Do not over-tighten. Tightening torque: Petrol Engine - 1.2 ~ 1.6 kgf.mDiesel Engine - 2.3 ~ 2.5 kgf.m
7. Pour the specified quantity of the recom- mended oil into the engine and replace the filler cap. Start the engine and ensure thatno oil leaks exist. Turn off the engine andafter a couple minutes, recheck the oil level.
WARNING: Prolonged and repeated contact with used engine oils may result in serious skin disor-ders including dermatitis and cancer. Avoidcontact with skin as far as possible andalways wash thoroughly after any contact.Keep used oils out of reach of children. It isillegal to pollute drains, water courses andsoil. Use only authorized waste collectionfacilities including civic amenity sites andgarages for the disposal of used oil and oilfilters. If in doubt, contact the local authorityfor disposal instructions. SG050A1-E
ENGINE COOLANT CHECKING AND REPLACING
WARNING: Do not remove the radiator cap when the engine is hot, since the system is pressur-ized and coolant may be ejected from theradiator resulting in scalding. SG050B1-E
Coolant recommendations Only ethylene glycol based coolant with a cor- rosion inhibitor suited to aluminium alloy enginecomponents should be used in the coolingsystem. No further additives or inhibitors shouldbe used. The coolant specific gravity should bechecked as prescribed in the maintenanceschedule to ensure adequate frost and corro-sion protection. In addition, the engine coolantmust be replaced at the specified interval sincethe corrosion inhibitor properties deteriorate withtime. It is important to note that whilst an increase in the concentration of anti freeze gives an in-crease in the level of frost protection, a solutionwhich is in excess of 65% anti freeze will resultin reduced frost protection and engine over-heating. Therefore the recommended concen-tration of 50% should not be exceeded forgeneral use.The use of methanol based anti freeze com-pounds may result in engine overheating andwill invalidate the vehicle warranty.

EMISSION CONTROL SYSTEMS
7-2
Purge Control Solenoid Valve
The purge control solenoid valve is controlled
by the ECU; when the engine coolant tempera- ture is low, and during idling, it closes, so thatevaporated fuel is not taken into the surge tank.After engine warm-up, during ordinary driving, itopens to introduce evaporated fuel to the surgetank. misfire and result in excessive loading of thecatalytic converter.
o Avoid idling the engine for periods longer than 10 minutes.
o Your Hyundai should not be either pushed or pulled to get it started. This can cause thecatalytic converter to overload.
o Take care not to stop your Hyundai over any combustible material such as grass, paper,leaves or rags.
o Do not touch the catalytic converter or any other part of the exhaust system while theengine is running.
o Remember that your Hyundai dealer is your best source of assistance.
JH010D1-E
3. EXHAUST EMISSION CONTROL
SYSTEM
EGR system ; For a Petrol Engine This system helps control oxides of nitrogen byrecirculating a portion of the exhaust gases intothe intake manifold, thereby reducing cylindercombustion temperatures. YH040A2-E
CATALYTIC CONVERTER
; For a Petrol Engine The catalytic converter is part of the exhaust emission control system. Its purpose is to re-move certain engine emission products fromthe engine's exhaust. It looks something like amuffler and is located underneath the car in theexhaust system. YH040B1-E
About the Catalytic Converter ; For a Petrol Engine
Exhaust gases passing through the catalytic converter cause it to operate at very high tem-peratures. As a result, the introduction of largeamounts of unburned petrol may cause it tooverheat and create a fire hazard. This can beavoided by observing the following:
o Use only unleaded fuel.
o Maintain your engine in good condition. Ex- tremely high converter temperatures can re- sult from improper operation of the electri-cal, ignition or M.P.I. system.
o If your engine stalls, pings, knocks, or is hard to start, take your car to your Hyundaidealer as soon as possible and have thedifficulty corrected.
o Avoid driving with a very low fuel level. If you run out of petrol, it could cause the engine to H020D01S-GAT CATALYTIC CONVERTER ; For a Diesel Engine All Hyundai vehicles are equipped with oxida- tion type catalytic converter to reduce the car-bon monoxide, hydrocarbons and particulatecontained in the exhaust gas. H020C01HP-EAT EGR SYSTEM ; For a Diesel Engine This system helps control oxides of nitrogen by recirculating a part of the exhaust gas into theengine, there by reducing cylinder combustiontemperature. The EGR system helps reduce Nox (Oxides of Nitrogen) emission gasses.
Catalytic ConverterH020A01HP

INDEX
10-2 E Emission Control System
.......................................................... 7-1 ~ 7-2
Engine Before starting the engine ............................................................... 2-2 Compartment (3.5 V6) ..................................................................... 6-1
Compartment (2.9 CRDi) ................................................................ 6-2
Coolant ............................................................................................ 6-6
Coolant temperature gauge ........................................................... 1-44
If the engine overheats ................................................................... 3-2
Number ............................................................................................ 8-1
Oil .................................................................................................... 6-3 Starting ............................................................................................ 2-4
Engine Exhaust Can Be Dangerous ................................................... 2-1
F Fan Speed Con trol ................................................................... 1-68, 1-77
Fog Light
Front .............................................................................................. 1-45
Rear .............................................................................................. 1-46
Front Seats Adjustable headrests ..................................................................... 1-11
Adjusting seatback angle .............................................................. 1-11
Driver's seat lumbar support control .............................................1-11
Seat adjustment ............................................................................ 1-10
Seat cushion height adjustment .................................................... 1-12
Seat fore/aft adjustment ................................................................ 1-10Fuel
Capacity .......................................................................................... 9-1
Diesel .............................................................................................. 1-1
Gauge ............................................................................................ 1-44
Unleaded petrol ............................................................................... 1-1
Fuel Filler Lid
Remote release ............................................................................. 1-62
Full-time 4WD Operation .................... ................................... 2-11 ~ 2-14
Fuses ................................................................................................ 6-17
G Glove Box ......................................................................................... 1-56
H Hatchback Door ................................................................................ 1-60
Hazard Warning System ................................................................... 1-50
Headlight Aiming Adjustment ............................................................ 6-21
Headlight Bulbs Replacement ........................................................... 6-20
Headlight Leveling Device System ................................................... 1-65
Heated Rear Window ........................................................................ 1-51
Heating and Ventilation Air flow control .............................................. 1-69 ~ 1-70, 1-78 ~ 1-79
Air intake control .................................................................. 1-68, 1-77
Defrosting/Defogging ..................................................................... 1-72
Temperature control ...................................................................... 1-70
High-Mounted Rear Stoplight ............................................................ 1-62
Horn .................................................................................................. 1-64