2005 Hyundai H-1 (Grand Starex) engine

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!WARNING:
o Improperly loading your car and trailer can serious affect its steer- ing and braking performance causing a crash in which youmay be seriously injured.
o For automatic transmission ve-
hicles, the trailer should be towedwith the towing vehicle unloaded, with the exception of the driver. Otherwise, the automatic trans-mission oil temperature may rise to a temperature that may result in serious damage of the auto- matic transmission. C190F02A-GAT Trailer or Vehicle Towing Tips
1. Before towing, check hitch and
safety chain connections as well as proper operation of the trailer run- ning lights, brake lights, and turn signals.
2. Always drive your vehicle at a mod- erate speed (Less than 100 km/h).
3. Trailer towing requires more fuel than normal conditions.
4. To maintain engine braking effi-
ciency and electrical charging per-formance, do not use fifth gear (manual transmission) or overdrive (automatic transmission).
5. Always secure items in the trailer to prevent load shift while driving.
6. Check the condition and air pres- sure of all tires on the trailer and your car. Low tire pressure can se- riously affect the handling. Alsocheck the spare tire.
7. The vehicle/trailer combination is
more affected by crosswind andbuffeting. When being passed by a large vehicle, keep a constant speed and steer straight ahead. If there is too much wind buffeting,slow down to get out of the othervehicle’s air turbulence.
8. When parking your car and trailer,
especially on a hill, be sure to followall the normal precautions. Turn your front wheel into the curb, set the parking brake firmly, and put thetransmission in 1st or "R" (manual transmission) or "P" (automatic transmission). In addition, placewheel chocks at each of the trailer’s tires.
9. If the trailer has electric brakes, start your vehicle and trailer mov-ing, and then apply the trailer brake controller by hand to be sure thebrakes are working. This lets you check your electrical connection at the same time.
10.During your trip, check occasion- ally to be sure that the load issecure, and that the lights and anytrailer brakes are still working.
11.Avoid jerky starts, sudden accel-
eration or sudden stops.
12.Avoid sharp turns and rapid lane changes.

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IN CASE OF EMERGENCY
21BLEEDING THE FUEL SYSTEM
CAUTION:
If overheating should occur when towing, (temperature gauge reads near red zone), taking the followingaction may reduce or eliminate the problem.
1. Turn off the air conditioner.
2. Reduce highway speed.
3. Select a lower gear when going uphill.
4. While in stop and go traffic, place
the gear selection in park or neu-tral and idle the engine at a higher speed.
! E090A01P-GAT (Diesel Motor) The fuel system should be bled to remove air as described in the illustra- tion if the fuel supply is exhaustedduring travel, when the fuel filter is replaced, or if the vehicle is not used for a long time.
1. Loosen the air plug at the top of the
fuel filter. E090A01P
13.Avoid holding the brake pedal down
too long or too frequently. This could cause the brakes to overheat, re- sulting in reduced braking efficiency.
14.When going down a hill, shift into a
lower gear and use the engine brak-ing effect. When ascending a long grade, downshift the transmissionto a lower gear and reduce speed to reduce chances of engine over- loading and/or overheating.
15.If you have to stop while going uphill, do not hold the vehicle inplace by pressing on the accelera-tor. This can cause the automatic transmission to overheat. Use the parking brake or footbrake.
NOTE: When towing, check transmission fluid more frequently.

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IN CASE OF EMERGENCY
23IF 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

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D010B01A-AAT If Engine Doesn't Turn Over or Turns Over Slowly
1. If your car has an automatic
transaxle, be sure the gear selector lever is in "N" or "P" and the emer-gency brake is set.
2. Check the battery connections to be
sure they are clean and tight.
3. Turn on the interior light. If the light dims or goes out when you operatethe starter, the battery is discharged.
4. Check the starter connections to be sure they are securely tightened.
5. Do not push or pull the vehicle to start it. See instructions for "Jump Starting". D010B02P
D010D01A-AAT If the Engine Stalls While Driving
1. Reduce your speed gradually, keep-ing a straight line. Move cautiously off the road to a safe place.
2. Turn on your emergency flashers.
3. Try to start the engine again. If your
vehicle will not start, contact a Hyundai dealer or seek other quali- fied assistance.
JUMP STARTING
!
HA1FL4001
WARNING:
The gas produced by the battery during the jump-start operation is highly explosive. If these instruc-tions are not followed exactly, seri- ous personal injury and damage to the vehicle may occur! If you arenot sure how to follow this proce- dure, seek qualified assistance. Automobile batteries contain sul-furic acid. This is poisonous and highly corrosive. When jump start- ing, wear protective glasses and becareful not to get acid on yourself, your clothing or on the car. E110A02P-GAT
Discharged battery
Booster battery
D010C01A-AAT If Engine Turns Over Normally but Does Not Start 1. Check fuel level. 2. With the key in the "OFF" position,check all connectors at ignition coils and spark plugs(For Gasoline En- gine) or check all connectors atglow plug and glow plug relay(For Diesel Engine). Reconnect any that may be disconnected or loose.
3. Check fuel line in the engine room. 4. If engine still refuses to start, call a
Hyundai dealer or seek other quali- fied assistance.

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IN CASE OF EMERGENCY
25IF THE ENGINE OVERHEATS
CAUTION:
o Do not allow the jumper cable clips to touch one another.
o Do not connect the jumper cable
to the negative terminal of the flat battery. The battery generates explosive gas, and a spark caused whenthe jumper cable is disconnected from the negative terminal could ignite this gas and cause an ex-plosion.
o Be careful that the jumper cable
becomes not caught in the cool-ing fan, etc.
! D030A01TB-AAT If your temperature gauge indicates overheating, you experience a loss of power, or hear loud pinging or knock- ing and the engine is probably too hot.If this happens to you, you should:
1. Pull off the road and stop as soon as
it is safe to do so.
2. Place the gear selector lever in "P"
(automatic transmission), or neutral (manual transmission) and set the parking brake. If the air conditioning is on, turn it off.
3. If engine coolant is running out un- der the car or steam is coming outfrom the hood, stop the engine. Donot open the hood until the engine coolant has stopped running or the steaming has stopped. If there is novisible loss of engine coolant and no steam, leave the engine running and check to be sure the enginecooling fan is operating. If the fan is not running, turn the engine off.
the other end to the engine block of the vehicle with the flat batteryat the point farthest from the battery.
8. Start engine as described "Starting the engine" in section 3.
9. After the engine is started, discon- nect the cables in the reverse order.
1. Both batteries must be 12V. The
capacity (Ah) of the battery supply- ing current should not be signifi- cantly below that of the discharged battery.
2. Use only heavy-duty jumper cables.
3. A discharged battery can freeze. A
frozen battery must be thawed out before connecting the jumper cables.
4. There should be no contact be-
tween the two vehicles; otherwisecurrent may flow when the positive terminal is connected.
5. The discharged battery must be correctly connected to the vehicleelectrical system.
6. Run the engine of the vehicle sup- plying current.
7. Connect the jumper cables as fol-
lows:
(1) Connect one end of one jumper cable to the positive terminal of the flat battery, and the other end to the positive terminal of the booster battery.
(2) Connect one end of the other jumper cable to the negative ter-minal of the booster battery, and

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4. Check to see if the water pump drivebelt 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.
!

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G290B03P-AAT Adjustment After Headlight Assembly Replacement If the vehicle has had front body repair and the headlight assembly has been replaced, the headlight aiming should be checked using the aiming screen asshown in the illustration. Turn on the headlight switch. (Low Beam Position)
1. Adjust headlights so that main axis
of light is parallel to center line of the body and is aligned with point "P"shown in the illustration.
2. Dotted lines in the illustration show
center of headlights.
5. Open the hood.
6. Draw the vertical line (through the
center of each headlight beam pat- tern) and the horizontal line (through the center of each headlight beam pattern) on the aiming screen.And then, draw a horizontal parallel line at 30 mm (1.18 in.) under the horizontal line.
7. Adjust each cut-off line of the low beam to the parallel line with a phillipsscrewdriver - VERTICAL AIMING.
8. Adjust each cut-off line of the low beam to the each vertical line with aphillips screwdriver - HORIZONTALAIMING.
Horizontal aiming
Verticalaiming
G290A01P-1
Truck
G290B01L
LW
H
H Cut-off line
Ground line
"P"
Horizontal line
30mm (1.18 in.) Vertical line
HEADLIGHT AIMING ADJUSTMENT
G290A03P-AAT Before performing aiming adjustment, make sure of the following.
1. Keep all tires inflated to the correct pressure.
2. Place the vehicle on level ground
and press the front bumper and rear bumper down several times.
3. See that the vehicle is unloaded
(except for full levels of coolant,engine oil and fuel, and spare tire, jack, and tools). Have the driver or equivalent weight placed in driver'sseat.
4. Clean the head lights lens and turn
on the headlight (Low beam).
Minibus/Van
G290A02P
Horizontal aiming
Verticalaiming

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HSRFL274
7. Push the bulb spring to remove the headlight bulb. HSRFL273
6. Turn the plastic cover counterclock- wise and remove it.
4. Using a spanner of the correct size,
remove the headlight assembly mounting bolts.
HSRFL272
5. Disconnect the power cord from the back of the headlight.
Replacement instructions:
1. Allow the bulb to cool. Wear eye
protection.
2. Open the engine hood.
3. Always grasp the bulb by its plastic base, avoid touching the glass. HSRFL270
G270A01P-GAT HEADLIGHT AND FRONT TURN SIGNAL LIGHT (Minibus/van)
Turn signal light
HSRFL271
Front position light
Headlight