2004 Hyundai Terracan fuel cap

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

VEHICLE MAINTENANCE REQUIREMENTS
5- 6
F060B01A-AAT
o Drive belts Inspect all drive belts for evidence of cuts, cracks, excessive wear or oil and replace ifnecessary. Drive belts should be checkedperiodically for proper tension and adjusted asnecessary. F060C01A-AAT
o Fuel filter A clogged filter can limit the speed at which the vehicle may be driven, damage the emissionsystem and cause hard starting. If an exces-sive amount of foreign matter accumulates inthe fuel tank, the filter may require replace-ment more frequently. After installing a new filter, run the engine for several minutes, and check for leaks at theconnections. Fuel filters should be installed bytrained technicians.
F060M01A-AAT o Engine oil and filterThe engine oil and filter should be changed at the intervals specified in the maintenanceschedule. If the car is being driven in severeconditions, more frequent oil and filter changesare required.
F060D01TB-AAT
o Fuel lines, fuel hoses and connec-
tions
Check the fuel lines, fuel hoses and connec-tions for leakage and damage. Have a trainedtechnician replace any damaged or leakingparts immediately.
WARNING (Diesel only): Never work on injection system with en-gine running or within 30 seconds aftershutting off engine. High pressure pump,rail, injectors and high pressure pipes aresubject to high pressure even after theengine stopped. The fuel jet produced byfuel leaks may cause serious injury, if ittouch the body. People using pacemak-ers should not move than 30cm closer tothe ECU or wiring harness within theengine room while engine is running,since the high currents in the CommonRail system produce considerable mag-netic fields. F060E01A-AAT
o Timing beltInspect all parts related to the timing belt for damage and deformation. Replace any dam-aged parts immediately. F060G01A-EAT
o Vapour hose and fuel filler cap The vapour hose and fuel filler cap should be inspected at those intervals specified in themaintenance schedule. Make sure that a newvapour hose or fuel filler cap is correctlyreplaced.
F060F01A-AAT
o Vacuum, crankcase
ventilation hoses
Inspect the surface of hoses for evidence of
heat and/or mechanical damage. Hard andbrittle rubber, cracking, tears, cuts, abrasions,and excessive swelling indicate deterioration.Particular attention should be paid to examinethose hose surfaces nearest to high heatsources, such as the exhaust manifold.
Inspect the hose routing to assure that the
hoses do not come in contact with any heatsource, sharp edges or moving componentwhich might cause heat damage or mechani-cal wear. Inspect all hose connections, suchas clamps and couplings, to make sure theyare secure, and that no leaks are present.Hoses should be replaced immediately if thereis any evidence of deterioration or damage.
F060A01A-AAT
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS

OWNER MAINTENANCE
6-2
G010C01HP-EAT
DIESEL ENGINE COMPARTMENT (2.9 CRDi)
1. Windscreen washer fluid reservoir
2. Brake fluid reservoir
3. Clutch fluid reservoir (Not all models)
4. Engine cover 5. Automatic transmission fluid level dipstick
(Vehicle with Automatic Transmission)
6. Battery
7. Fuse and relay box
8. Air cleaner 9. Engine oil level dipstick
10. Radiator cap
11. Engine oil filler cap
12. Fuel filter
13. Power steering fluid reservoir
14. Coolant reservoir capG010C01HP-D
CAUTION: When inspecting or servicing the en- gine, you should handle tools andother heavy objects carefully so thatthe plastic cover of the engine is notdamaged.
12
34 56
8 9 10 11 12 7 137
14

OWNER MAINTENANCE
6-12
3. If the transmission fluid level is low, use a
funnel to add transmission fluid through the dipstick tube until the level reaches the "HOT"range. Do not overfill.
WARNING: The electric engine cooling fan automatical-
ly switches on and off according to engine temperature. Be careful to keep away fromthe fan during this check as it may switch onat any time.
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 move
G110D03Y
Fluid level should be within "HOT" range
than 30cm closer to the ECU or wiring har- ness within the engine room whilst engineis running, since the high currents in theCommon Rail system produce considerablemagnetic fields.
NOTE: Only lint free cloth should be used for wip-
ing the dipstick. The presence of lint within the transmission may cause problems withthe normal function of the transmission.
G120E01HP.DAG
SG120A1-E
BRAKE SYSTEM CHECKING CAUTION: Correct operation of the braking system is essential to the safe operation of the vehicleand therefore, any maintenance operationsother than those listed below should beentrusted to a Hyundai dealer. SG120C2-E
Brake Fluid Recommendations Only brake fluid conforming to DOT 3 or DOT 4 specifications or higher may be used in thebraking system. Care should be taken to ob-serve the instructions and precautions printedupon the container. SG120D1-E
Brake Fluid Level
The fluid level in the brake fluid reservoir shouldbe checked periodically. The level should bebetween the "MIN" and "MAX" marks on theside of the reservoir. If the level is at or belowthe "MIN" mark, fluid should be added havingcarefully cleaned the area surrounding the res-ervoir cap to ensure that dirt is not allowed toenter the system. It should be borne in mindthat the brake fluid level will decrease slightlyas the friction linings of the pads and shoesbecome worn and that this is a normal condi-tion. WARNING: Brake fluid is hygroscopic and should never be stored in an unsealed container. Thepresence of water in the braking system willcause vapour locks and increase the possi-bility of brake fade along with promoting

OWNER MAINTENANCE 6-21
G270A02HP
WARNING: The halogen bulb contains gas under pres- sure and if impacted could shatter, resultingin flying fragments. Always wear eye pro-tection when servicing the bulb. Protect thebulb against abrasions or scratches andagainst liquids when lighted. Turn the bulbon only when installing in a headlight. Re-place the headlight if damaged or cracked.Keep the bulb out of the reach of childrenand dispose of the used bulb with care.
Replacement instructions:
1. Allow the bulb to cool. Wear eye protection.
2. Always grasp the bulb by its plastic base, avoid touching the glass.
3. Disconnect the power cord from the bulb base in the back of the headlight.
4. Push the bulb spring for removing the head- light bulb.
5. Remove the protective cap from the re- placement bulb and install the new bulb by matching the plastic base with the headlighthole. Retighten the bulb spring and recon-nect the power cord.
6. Use the protective cap and carton to dis- pose of the old bulb.
7. Check for proper headlight aim. G270A02Y-AAT
HEADLIGHT BULB
G270A01HP
G290A01HP-EAT
HEADLIGHT AIMING ADJUSTMENT
G290A01HP
Horizontal aiming (Low Beam)
Vertical aiming (Low Beam)
Before performing aiming adjustment, make sure of the following.
1. Keep all tyres inflated to the correct pres- sure.
2. Place the vehicle on level ground and press the front bumper & rear bumper down sev-eral times. Place vehicle at a distance of118.1 in. (3m) from the test wall.
3. See that the vehicle is unloaded (except for full levels of coolant, engine oil and fuel, andspare tyre, jack, and tools). Have the driveror equivalent weight placed in driver's seat.
4. Clean the headlight lens and turn on the headlight.
5. Open the bonnet. Vertical aiming (High Beam)
Horizontal aiming(High Beam)

EMISSION CONTROL SYSTEMS 7-1
vehicle may be damaged. You should inspect the exhaust system each time the car is raisedfor lubrication or oil change. To check condition
1. Holes and gas leaks due to corrosion, dam-
age, etc., should be rectified.
2. The joints should be checked for loose con- nections and gas leakage.
3. The hanger rubber and brackets should be checked for damage. DH010B1-E
1. CRANKCASE EMISSION CONTROL
SYSTEM ; For a Petrol Engine
The positive crankcase ventilation system is
employed to prevent air pollution caused by blow-by gases being emitted from the crank-case.
This system supplies fresh air to the crankcase
through the air cleaner. Inside the crankcase,the fresh air mixes with blow-by gases, thenpasses through the PCV valve into the intakesystem.
ZH010C1-E
2. EVAPORATIVE EMISSION CON-
TROL SYSTEM ; For a Petrol Engine
The Evaporative Emission Control System is designed to prevent fuel vapors from escapinginto the atmosphere.
Canister While the engine is inoperative, fuel vaporsgenerated inside the fuel tank are absorbed andstored in the canister. When the engine isrunning, the fuel vapors absorbed in the canis-ter are drawn into the induction system throughthe purge control solenoid valve.
YH000A1-A
7. EMISSION CON-
TROL SYSTEMS
YH020A1-E
EXHAUST GAS WARNING
Exhaust gases contain carbon monoxide, a
potentially toxic gas that is colorless and odor-less. Avoid breathing exhaust gases.
o Do not run the engine in confined areas, such as garages, any longer than neces- sary to move the car in or out.
o Do not drive with the trunk open. An open trunk may draw exhaust gases into the pas-senger compartment. If you must drive withthe trunk open, drive only with all the win-dows wide open and the blower motor onhigh speed.
o If it is necessary to sit in a parked car with the engine running for more than a shortperiod, adjust your heating system to forceoutside air into the car by placing the airselector button of the heater in the FRESHAIR position and mode control in the VENTposition. Set the fan at high speed and thecontrols in any position desired.
Inspect the exhaust system Whenever a change is noticed in the sound of
the exhaust system, the underside or rear of the ZH010A1-E EMISSION CONTROL SYSTEMS (Not all models) Your Hyundai is equipped with an emission control systems. There are three emission control systems which are as follows. (1) Crankcase emission control system (2) Evaporative emission control system(3) Exhaust emission control system In order to assure the proper function of the emission control system, it is recommendedthat you have your car inspected and main-tained by an authorized Hyundai dealer in ac-cordance with the schedule in this manual.
7

VEHICLE SPECIFICATIONS 9-1
Option Spare
J050A02HP-GAT BRAKE Dual hydraulic with brake booster Ventilated discDisc type Cable operated on rear wheel
TypeFront brake type Rear brake type
Parking brake
J030A01HP-EAT TYRE
16.5 lmp.gal (75 litre)
9. VEHICLE SPECIFICATIONS
Overall length Overall widthOverall height Wheel base Wheel tread
Front Rear
Type Wheel free playOil pump typeBall and nut, torsion bar type (Integral type) 0 ~ 1.18 in. (0 ~ 30 mm)Vane type
J010A01HP-EAT MEASUREMENT J020A01HP-EAT POWER STEERING J060A01HP-EAT FUEL SYSTEM
185.4 (4710)
73.2 (1860) 70.6 (1795)
108.2 (2750)
60.2 (1530)60.2 (1530)
ITEM Battery Alternator
J040A02HP-EAT ELECTRICAL
PETROL
MF 68 AH
120 A (13.5 V) DIESEL
MF 100 AH
110 A (12 V)
Fuel tank capacity
9
in. (mm) 235/75 R15 225/65 R16
Full Size

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