2005 Hyundai H-1 (Grand Starex) fuel cap

1
BEFORE DRIVING YOUR VEHICLE
3
B030A01P-GAT BEFORE OPERATION PRECAUTIONS FOR NEWVEHICLE The performance and life of a vehicle depend largely on how the vehicle is handled when new.To maintain the parts smoothly and sustain high performance for a long time to come, be sure to observe thefollowing points. Make sure that your vehicle does not miss the first 5,000 km inspec- tions. After the first 5,000 km of driving, take your vehicle to your nearest service shop for inspection. B040A01P-GAT OPERATION IN FOREIGN COUN- TRIES If you are going to drive your Hyundai in another country, be sure to:
o Observe all regulations regarding
registration and insurance.
o Determine that acceptable fuel is available.
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B055A02P-GAT LOADING YOUR VEHICLE Never load the luggage and people to exceed GVWR(MLW) and GAWR ofyour vehicle. You can find the GVWR(MLW) and GAWR -maximum loading capacities-on the VIN plate. The GVWR(Gross Vehicle Weight Rating) or MLW(Maximum LoadedWeight) means total weight of the ve- hicle, all occupants, fuel and cargo. And GAWR means the maximumweights that the front and rear axles can endure the weights including ve- hicle itself weight.
WARNING:
Improperly loading your car canseriously affect its steering and braking performance causing a crash in which you may be seri-ously injured or killed. NOTE: Your warranty does not cover parts or components that fail because of overloading.

1
BEFORE DRIVING YOUR VEHICLE
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B200C01H-GAT Fuel tank cap key (Truck) The fuel tank cap can be opened when- ever you fuel-up. You lock the fuel tankcap by turning the key toward the front of the vehicle and unlock it by turning it toward the rear.The fuel tank cap is located at the left side of the vehicle body. GT10221A
!WARNING:
Fuel vapors are dangerous. Before refueling, always stop the engine and never allow sparks or open flames near the filler area. If youneed to replace the filler cap, use a genuine Hyundai replacement part. If you open the fuel filler cap duringhigh ambient temperatures, a slight "pressure sound" may be heard. This is normal and not a cause forconcern. Whenever you open the fuel filler cap, turn it slowly.
WINDOW
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B230A01P-GAT FRONT DOOR WINDOW GLASS Manual type Turn the window regulator handle to raise or lower the window.
WARNING:
When opening or closing the win- dows, make sure your passenger's arms and hands are safely out of the way. CLOSE
GT10260A
OPEN

44IN CASE OF EMERGENCY
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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 (Diesel Motor) If the fuel filter warning lamp illumi- nates during driving, it indicates that water 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
26
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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6
VEHICLE MAINTENANCE REQUIREMENTS
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G080E01P-GAT
o Vacuum and Crankcase
Ventilation Hoses
Inspect the surface of hoses for evi- dence of heat and/or mechanical dam- age. Hard and brittle rubber, cracking, tears, cuts, abrasions, and excessiveswelling indicate deterioration. Particu- lar attention should be paid to examin- ing those hose surfaces nearest tohigh heat sources, such as the ex- haust manifold. Inspect the hose routing to assure that the hoses do not come in contact with any heat source, sharp edges or mov- ing component which might cause heatdamage or mechanical wear. Inspect all hose connections, such as clamps and couplings, to make sure they aresecure, and that no leaks are present. Hoses should be replaced immedi- ately if there is any evidence of dete-rioration or damage. G080F01P-GAT
o Fuel Hose, Vapor Hose and
Fuel Filler Cap
The fuel hose, vapor hose and fuelfiller cap should be inspected at those intervals specified in the maintenance schedule. Make sure that a new fuelhose, vapor hose or fuel filler cap is correctly replaced. Consult your Hyundai dealer if you have any ques-tions. G080G01P-GAT
o Air Cleaner Filter
A genuine Hyundai part is recom- mended for replacement of the air cleaner filter. G080H01P-GAT
o Spark Plugs (Gasoline) Make sure to install new spark plugs of the correct heat range. G080I01P-GAT
o Drive Belts Inspect all drive belts (water pump and alternator) for evidence of cuts, cracks, excessive wear or oiliness, and re- place if necessary. Drive belts shouldbe checked periodically for proper ten- sion and adjusted as necessary. G080J01P-GAT
o Engine Coolant The coolant should be changed at those intervals specified in the Vehicle Maintenance Requirements Section. G080K01P-GAT
o Timing Belt Inspect all parts related with the timing belt for damage and deformation. Re-place any damaged parts.

7EMISSION CONTROL SYSTEM
2EMISSION CONTROL SYSTEM
H010A01P-GAT (Gasoline) Your Hyundai is equipped with an emission control system. There are three emission control sys- tems which are as follows.
(1) Crankcase emission control sys- tem
(2) Evaporative emission control sys- tem
(3) Exhaust emission control systemIn order to assure the proper function of the emission control systems, it is recommended that you have your vehicle inspected and maintained byan authorized Hyundai dealer in ac- cordance with the maintenance sched- ule in this manual. H020A01P-GAT
1. Crankcase Emission Control
System
The positive crankcase ventilation
system is employed to prevent airpollution caused by blow-by gases being emitted from the crankcase.This system supplies fresh air to the crankcase through the air cleaner. Inside the crankcase, the fresh airmixes with blow-by gases, then passes through the PCV valve into the induction system.
H080A01P-GAT PCV Valve The crankcase ventilation system must be kept clean to maintain good engine performance. Periodic servicing is required to re- move combustion products from the PCV valve. H030A01P-GAT
2. Evaporative Emission Control
System (except canister)
The Evaporative Emission ControlSystem is designed to prevent fuel vapors from escaping into the atmo-sphere.If the fuel-vapor vent line is cloggedor damaged, the fuel-vapor mixturewill escape into the atmosphere and cause insufficient emission control. Disconnect the line at both ends, and blow it clean with compressed air. Remove the filler cap from the filler pipe, and check to see if there is evidence that the packing contact to the filler pipe is faulty. The overfilllimiter (2-way valve) installed on the vapor line between the canister inlet and fuel tank outlet must be checkedfor correct operation.

9 VEHICLE SPECIFICATIONS
2
2WD
1,885(74)
SHORT
3
VAN
4,695(184)
1,820(71)1,900(74)
2,810(110)
1,570(61)1,545(60)
Front Rear
J010A03P-GAT MEASUREMENT J010A02P-GAT MEASUREMENT
J020A02P-GATFUEL TANK SYSTEMmm (in.)
MINIBUS, VAN
Overall length Overall widthOverall height Wheel base Wheel tread
ITEMS FUEL TANK CAPACITYMINIBUS, VAN 65L TRUCK
70LLONG(1ton)
STANDARD
5085 (200)1820 (71)
3080 (121)
1570 (62) 1408 (55) EXTRA LONG (1.25 ton)
STANDARD
5415 (213)1820 (71)
3280 (129)
1570 (62)1408 (55)TRUCK
Overall length Overall width Wheel base Wheel tread
Front Rear
SUPER
mm(in.)
12

9

1,970(77)
6
VAN
3
VAN
5,035(198)

1,980(77)
3,080(121)

9
4,695(184)
1,885(74)
1,570(61)1,545(60)
4WD
4,825(189)

1,995(78)
1,565(61)1,560(61)
6
VAN
LONG
7

10
INDEX
3
D
DAY/NIGHT INSIDE REARVIEW MI RROR .............2-34
DEFROSTING/DEFOGGING ...................................2-43
DIGITAL CLOCK ...................................................... 2-37
DOOR LOCKS .......................................................... 1-12
DRINK HOLDER ....................................................... 2-35
DRIVING FOR ECONOMY ......................................3-25
DRIVING WITH ELECTRONIC DUAL-RANGE AUTOMATIC TRANSM ISSION ............................. 3-13
EEMISSION CONTROL SYSTEM ............................... 7-2
ENGINE ...................................................................... 9-3
ENGINE COMPARTMENT ......................... ................ 8-2
ENGINE COOLANT .................................................. 8-10
ENGINE COOLANT TEM PERATURE GAUGE.......2-12
ENGINE NUMBER ..................................................... 1-5
ENGINE OI L ............................................................... 8-7
ENGINE RPM ADJUSTMENT KNOB ......................2-24
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS .............. ...........................6-12
FFOUR-WHEEL DRIVE (4WD) ..................................3-15
FRONT DOOR EDGE WARNING LIGHT ...............2-25
FRONT DOOR WINDOW GLASS ...........................1-25
FRONT FOG LIGHT SWITCH .................................2-25FRONT/REAR WINDOW DEFROSTER
SWITCH .. 2-26
FUEL GAUGE ........................................................... 2-12
FUEL TANK CAPACITY ............................................. 9-2
FUSE PANEL DESCRIPTION ..................................4-40
GGENERAL CHECKS ................................................... 8-6
GOOD BRAKING PRACTICE ..................................3-22
HHAZARD WARNING SYSTEM................................ 2-26
HEADLIGHT AIMING ADJUSTMENT ......................4-29
HEADLIGHT LEVELING DEVICE SYSTEM ............2-23
HEADREST ............................................................... 1-37
HEATING AND COOLING CONTROL ....................2-38
HEATING CONTROLS ............................................. 2-42
HEIGHT ADJUSTABLE FRONT SEAT SHOULDER BELT ...................................................................... 1-41
HIGH-MOUNTED REAR STOP LIGHT ...................2-25
HOLD OPEN LOCK SYSTEM................................. 1-13
HOOD RELEASE ..................................................... 1-23
HORN ........................................................................ 2-37