2005 Hyundai H-1 (Grand Starex) clutch

6VEHICLE MAINTENANCE REQUIREMENTS
6
50 40I I I I I I I I I I I I
KILOMETERS X 1000MONTHS
NO.
1 2 3 4 5 6 7 8 9
1011 12 13 14 15 16 17 18 19 20 21 22 DESCRIPTION
GENERAL MAINTENANCE ENGINE COOLANT MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL TRANSFER CASE OIL REAR AXLE OIL CLUTCH / BRAKE PEDAL FREE PLAY CLUTCH / BRAKE OIL RESERVOIR BRAKE HYDRAULIC FLUID FRONT BRAKE PADS FRONT BRAKE CALIPERS / CYLINDERS / DISC REAR BRAKE DRUMS / LININGS / CYLINDERS HANDBRAKE TIRE CONDITION / PRESSURE EXHAUST SYSTEM / MOUNTING STEERING JOINT / RACK / BOX OIL LEAKS SUSPENSION JOINT / SEALS FRONT WHEEL BEARING ENGINE COOLANT HOSES BRAKE PIPE CORROSION SEATBELTS / MOUNTINGS HEAD LAMPS AIR CONDITIONER FILTER (FOR EVAPORATOR AND BLOWER UNIT)
G020A06P-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
80 64
I
R II I I I I I I I I I I I I I 90 72
I I I I I I I I I I I I I
70 56
I I I I I I I I I I I I
6048
I I I I I I I I I I I I I I I I I I
4032
I
R II I I I I I I I I I I I I I
30 24
I I I I I I I I I I I I I
20 16
I I I I I I I I I I I I I I I I I108
I I I I I I I I I I I I
5 4
See Note (1)
Note : (1) For every 40,000 KM or 24 months, whichever occurs first : "R" (2) For every 20,000 KM or 12 months, whichever occurs first : "I"
(3) For every 48,000 KM or 24 months, whichever occurs first : "R"
(4) For every 15,000 KM or 12 months, whichever occurs first : "R"
See Note (4)
See Note (2) See Note (3)

6VEHICLE MAINTENANCE REQUIREMENTS
10
45 36II
R II I I I I
R
15 12
II I I I I I I I
R
G060A05P-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
See Note (2)
KILOMETERS X 1000 MONTHS
NO.
1 2 3 4 5 6 7 8 9
1011 12 13 14 15 16 17 18 19 20 DESCRIPTION
GENERAL MAINTENANCE ENGINE COOLANT MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL TRANSFER CASE OIL REAR AXLE OIL CLUTCH/BRAKE PEDAL FREEPLAY CLUTCH/BRAKE OIL RESERVOIR BRAKE HYDRAULIC FLUID FRONT BRAKE PAD FRONT BRAKE CALIPERS/CYLINDERS/DISC REAR BRAKE DRUMS/LININGS/CYLINDERS HAND BRAKE TIRE CONDITION/PRESSURE EXHAUST SYSTEM/MOUNTING STEERING JOINT/RACK/BOX/OIL LEAKS SUSPENSION JOINT/SEALS FRONT WHEEL BEARING ENGINE COOLANT HOSES BRAKE PIPE CORROSION AIR CONDITIONER FILTER (FOR EVAPOERATOR AND BLOWER UNIT)
75 60
II I I I I I I I
R 90 72
I
R R I I I I I I I I I I I I I I
R
6048
II I I I I I I I I I I I I I I I
R
3024
II I I I I I I I I I I I I I I I
R
7.5
6
See Note (1)
Note: (1) For every 45,000 KM or 24 months, whichever occurs first : "R"
(2) For every 48,000 KM or 24 months, whichever occurs first : "R"

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
8
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
17
!
On a vehicle with the brake fluid
warning lamp, the brake fluid level is monitored by a float. When the brake fluid level falls to below the "MIN" mark, the brake fluid warning lamplights up.
WARNING:
o Use only the specified brake fluid. Also, the additives in dif-ferent brands may result in a chemical reaction when mixed together, so avoid mixing differ-ent brands if possible.
o Use extreme caution in filling
the brake fluid because it is toxicand corrosive, and it can harm your eyes and damage painted surface. If the fluid gets in youreyes, flush your eyes with clean water.
CHECKING THE AUTOMATIC TRANSMISSION FLUID
I120A02P-GAT (If installed) Transmission fluid in the automatic transmission should be changed at those intervals specified in the ve- hicle maintenance schedule in Sec-tion 6. NOTE: Automatic transmission fluid is a red color. As driving distance in- creases, the fluid color turns dark-ish red gradually. It is a normal condition and you should not judge the need to replace basedupon the changing color.You must replace the automatictransmission fluid in accordance with intervals specified in the ve- hicle maintenance schedule in sec-tion 6.CHECKING THE CLUTCH FLUID
I110A01P-GAT (If installed) In the case of vehicles with the hy- draulic operating clutch, the reservoir for the clutch fluid also serves as the reservoir for the brake fluid. See theparagraph on the brake fluid.

8
DO-IT YOURSELF MAINTENANCE
21TAIL GATE WINDOW WASHER FLUID
I140A02P-GAT (Minibus/Van) (If installed) After opening the cover of quarter trim panel which is located on the left side of quarter trim, check the fluid level. If the fluid level is low, refill thewasher fluid. HSRFL140CHECKING THE FREEPLAY
G150A01A-GAT Steering Wheel To check the steering wheel freeplay, stop the car with the wheels pointed straight ahead and gently move the steering wheel back and forth. Usevery light finger pressure and be sen- sitive to changes in resistance that mark the limits of the freeplay. If thefreeplay is greater than specified, have it inspected by your Hyundai dealer and adjusted or repaired if necessary. 30 mm (1.18 in.)
G160A01A-GAT Clutch Pedal With the engine off, press lightly on the clutch pedal until you feel a change in resistance. This is the clutch pedal freeplay. The freeplay should be withinthe limits specified in the illustration. If it is not, have it inspected by your Hyundai dealer and adjusted or re-paired if necessary. 6 ~ 13 mm (0.24 ~ 0.51 in.)
HSROM109 G160A01E

9
VEHICLE SPECIFICATIONS
5
J060A08P-GAT QUANTITY (LITER)
Minibus, Van : 1.3 0.8
Minibus : 13, Van : 10, Truck : 7.2As requiredAs required
Minibus, Van : 2.6, Truck : 1.7 As required
OIL & GREASE STANDARD
HYUNDAI GENUINE PARTS MTF 75W/85 (API GL-4) MOBIL DEXRON-II or DIAMOND ATF SP-I DIAMOND ATF SP II PSF-3HIGH QUALITY ETHYLENE GLYCOL BASE FORALUMINUM RADIATORSAE J 1703 EQUIVALENTSAE J310a, MULTI-PURPOSE GREASE NLGI-2 OREQUIVALENT.API GL-4 (MS517-15) : SAE 90, 140API GL-5 (MS517-15) : SAE 80
ITEMS
MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION OIL TRANSFER CASE OIL POWER STEERING OIL COOLANTCLUTCH & BRAKE FLUIDFRONT, REAR WHEEL BEARINGREAR AXLE STEERING GEAR BOX
GASOLINE DIESEL
GASOLINE
DIESEL 2.0
2.6 N/A : 2.4 2.5 4D56 TCI : 2.42.5 CRDi TCI : 3.2 7.53
2.6 N/A(long van): 8.5 2.6 N/A: 7 2.5 4D56 TCI(2WD) : 7.92.5 4D56 TCI(4WD) : 9.832.5 CRDi TCI(2WD) : 8.32.5 CRDi TCI(4WD) : 11.7

10INDEX
2
A ADJUSTABLE FRONT SEATS ................................1-30
AIR CONDITIONER FILTER ........................... 2-47, 8-15
AIR CONDITIONING CARE .....................................8-14
AIR CONDITIONING SYSTEM ................................2-44
ALTIMETER .............................................................. 2-18
ANTENNA ................................................................. 2-73
ANTI-LOCK BRAKE SYSTEM ................................. 3-23
APPEARANCE CARE ................................................ 5-2
ASHTRAY ................................................................. 2-36
AUDIO FAULT CODE .............................................. 2-70
AUDIO SYSTEM Cassette Tape Player Operation (H240, H280)...................................................................... 2-54, 2-65
Compact Disc Player Operation (H260, H280)
...................................................................... 2-59, 2-67
Stereo Radio Operation (H240, H260, H280) ............................................................ 2-51, 2-56, 2-62
AUTOMATIC TRANSMISSION .................................. 3-9
AUTOMATIC TRANSMISSION FLUID ....................8-17
AUXILIARY SEAT ..................................................... 1-36BBACK WARNING
SYSTEM ..................................... 3-24
BATTERY ................................................................. 8-13
BEFORE STARTING THE ENGINE .......................... 3-2
BI-LEVEL HEATI NG ................................................. 2-42
BLEEDING THE FUEL SYSTEM ............................ 4-21
BRAKE FLUID .......................................................... 8-16
BRAKE PEDAL ......................................................... 3-21
BRAKE SYSTEM ...................................................... 3-19
BULB WATTAGE ...................................................... 4-38
CCARE OF CASSETTE TAPES ................................ 2-72
CARE OF DISC ........................................................ 2-71
CARRYING CHILDREN ............................................ 1-15
CATALYTIC CONVERTER .................. ...................... 7-3
CENTRAL DOOR LOCKS ......... ...............................1-14
CHANGING A FLAT TIRE ......................................... 4-7CHANGING AND REPLACING FUSES ..................4-27
CHECKING THE DRIVE BELTS .............................. 8-22
CHECKING THE FREEPLAY................................... 8-21
CHILD PROTECTION SLIDE DOOR .......................1-15
CHILD RESTRAINT SYSTEM ..................................1-43
CIGARETTE LIGHTER ............................................. 2-27
CLUTCH FLUID ........................................................ 8-17