2005 Hyundai Terracan manual transmission

3
WHAT TO DO IN AN EMERGENCY
7
!
CHANGING A FLAT TIREIF YOU HAVE A FLAT TIRE
D050A01HP-GAT If a tire goes flat while you are driving:
1. Take your foot off the accelerator pedal and let the car slow down while driving straight ahead. Do not apply the brakes immediately or at- tempt to pull off the road as this maycause a loss of control. When the car has slowed to such a speed that it is safe to do so, brake carefullyand pull off the road. Drive off the road as far as possible and park on firm, level ground. If you are on adivided highway, do not park in the median area between the two traffic lanes.
2. When the car is stopped, turn on your emergency hazard flashers,set the parking brake and put thetransmission in "P" (automatic trans- mission) or reverse (manual trans- mission).
3. Have all passengers get out of the car. Be sure they all get out on theside of the car that is away fromtraffic.
4. Change the tire according to the
instructions provided as following. D060A02HP-GAT The procedure described on the fol- lowing pages can be used to rotate tires as well as to change a flat tire.When preparing to change a flat tire, check to be sure the gear selector lever is in "P" (automatic transmission)or reverse gear (manual transmission) and that the parking brake is set, then:
D060A01HPWARNING:
Your vehicle is equipped with tires designed to provide for safe ride and handling capability. Do not use a size and type of tireand wheel that is different from the one that was originally installed on your vehicle. It can affect the safetyand performance of your vehicle, which could lead to handling fail- ure or rollover and serious injury.When replacing the tires, be sure to equip all four tires with the tire and wheel of the same size, type, tread, brand and load-carrying capacity. If you nevertheless decide to equipyour vehicle with any tire/wheel combination not recommended by Hyundai for off-road driving, youshould not use these tires for high- way driving.

5
VEHICLE MAINTENANCE REQUIREMENTS
7
F030C08HP-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
Note: (1) FOR EVERY 24 MONTHS OR 45,000 KM, WHICHEVER OCCURS FIRST : "R" DESCRIPTION
GENERAL MAINTENANCE COOLING SYSTEM COOLANT MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSION FLUID BRAKE HOSES AND LINES BRAKE FLUID, CLUTCH FLUID REAR BRAKE DRUMS/LININGS, PARKING BRAKE BRAKE PADS, CALIPERS AND ROTORS EXHAUST PIPE AND MUFFLER SUSPENSION MOUNTING BOLTS STEERING GEAR BOX, LINKAGE & BOOTS/ LOWER ARM BALL JOINT, UPPER ARM BALL JOINT POWER STEERING PUMP AND HOSES DRIVE SHAFTS AND BOOTS AIR CONDITIONING REFRIGERANT TRANSFER CASE OIL AXLE GEAR OIL PROPELLER SHAFT CLEAN, BOLT RETIGHTEN AIR CONDITIONER FILTER (For Evaporator and Blower Unit)
NO.
1
2 3 4 5 6 7 89
1011 12 1314 15 1617 18
120
96
I
R I I I I I I I I I II I I I I I
R
105
84
I I I I I I I I I I II I I
R R
90 72
I
R I
R II I I I I I II I I I I I
R
7560
I I I I I I I I I I II I I I
R
60 48
I
R II I I I I I I I II I I I
R
I
R
4536
I I I I I I I I I I II I I I
R
30 24
I
R II I I I I I I I II I I I I I
R
1512
I I I I I I I I I I II I I
R R
KILOMETERS X 1000 MONTHS
European Community Only Except European Community
See Note (1)GASOLINE ENGINE DIESEL ENGINE

5VEHICLE MAINTENANCE REQUIREMENTS
8
A, B, C, D, E, F, G, H, I, K A, B, F, G, H, I, JC, E G, H, I, JD, E, F, GC, D, E, G, H, I C, D, E, G, H, I C, D, E, F C, D, E, F A, C, D, E, F, G, H, I, J A, C, E, F, G, H, I C, E, G, H, I C, E, G, H, I C,E
ENGINE OIL AND FILTER (Gasoline Engine) ENGINE OIL AND FILTER (Diesel Engine (2.5 TCI))ENGINE OIL AND FILTER(Diesel Engine (2.9 CRDi))AIR CLEANER FILTERSPARK PLUGS (For Gasoline Engine) TIMING BELT BRAKE PADS, CALIPERS AND ROTORSREAR BRAKE DRUMS/LININGS, PARKING BRAKESTEERING GEAR BOX, LINKAGE AND BOOTS/LOWER ARM BALL JOINT, UPPER ARM BALL JOINTDRIVE SHAFTS AND BOOTS MANUAL TRANSMISSION OIL AUTOMATIC TRANSMISSIONFLUIDTRANSFER CASE OIL *
1
AXLE GEAR OIL * 1
AIR CONDITIONER FILTER (For Evaporator and Blower Unit)
European Community Only Except European Community
F040A07HP-GAT The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals. R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
R R R R
I I I I
RRR RR
EVERY 7,500 KM OR 6 MONTHS EVERY 4,000 KM EVERY 3,000 KMEVERY 7,500 KM OR 6 MONTHSEVERY 5,000 KM OR 6 MONTHSMORE FREQUENTLYMORE FREQUENTLY EVERY 60,000 KM OR 48 MONTHS MORE FREQUENTLYMORE FREQUENTLY MORE FREQUENTLY EVERY 15,000 KM OR 12 MONTHS EVERY 100,000 KMEVERY 45,000 KM EVERY 40,000 KM EVERY 100,000 KMMORE FREQUENTLYMORE FREQUENTLY
SEVERE DRIVING CONDITIONS
A - Repeatly driving short distance of less than 8km(5miles) in normal temperature or less than 16km(10miles) in freezing temperature
B - Extensive engine idling or low speed driving for long distances
C - Driving on rough, dusty, muddy, unpaved, graveled or salt- spread roads
D - Driving in areas using salt or other corrosive materials or in very
cold weather
DRIVING
CONDITION
MAINTENANCE INTERVALS
MAINTENANCE
OPERATION
MAINTENANCE ITEM
E - Driving in sandy areas
F - Driving in heavy traffic area over 32°C(90°F)
G - Driving on uphill, downhill, or mountain road
H - Towing a Trailer, or using a camper, or roof rack
I - Driving as a patrol car, taxi, other commercial use or vehicle towing
J - Driving over 170 Km/h(100 MPH)
K - Frequently driving in stop-and-go conditions
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
European Community Only Except European Community Europe Countries Only Except Europe Countries
*1: Transfer Case Oil and Axle Gear Oil should be checked (and replaced if necessary) anytime they have been submerged in water
over 40cm (15.7 in.) deep.

5
VEHICLE MAINTENANCE REQUIREMENTS
11
F070E03HP-GAT
o Automatic Transmission Fluid
The fluid level should be in the "HOT" range of the dipstick, after the engine and transmission are at normal operat- ing temperature. Check the automatictransmission fluid level with the engine running and the transmission in neu- tral, with the parking brake properlyapplied. Use MOBIL DEXRON-II when adding or changing fluid.
F070D01A-AAT
o Manual Transmission Oil
Inspect the manual transmission oil according to the maintenance sched- ule.
NOTE: If the oil level is low, check for possible leaks before adding oil. Donot overfill. F070F01A-AAT
o Brake Hoses and Lines
Visually check for proper installation,
chafing, cracks, deterioration and any leakage. Replace any deteriorated or damaged parts immediately.
F070G02A-AAT
o Brake Fluid
Check brake fluid level in the brake
fluid reservoir. The level should bebetween "MIN" and "MAX" marks on the side of the reservoir. Use only hydraulic brake fluid conforming to DOT3 or DOT 4.
F070H01A-AAT
o Rear Brake Drums/ Linings
Parking Brake
Check the rear brake drums and lin-
ings for scoring, burning, leaking fluid,broken parts, and excessive wear. In-spect the parking brake system in- cluding the parking brake lever and cables. For detailed service proce-dures, refer to the Shop Manual. F070J01A-AAT
o Brake Pads, Calipers and
Rotors
Check the pads for excessive wear, discs for run out and wear, and cali- pers for fluid leakage. F070K01A-AAT o Exhaust Pipe and Muffler Visually inspect the exhaust pipes, muffler and hangers for cracks, dete- rioration, or damage. Start the engine and listen carefully for any exhaustgas leakage. Tighten connections or replace parts as necessary. F070L01A-AAT o Suspension Mounting Bolts Check the suspension connections for looseness or damage. Retighten to the specified torque.

Engine Compartment ................................................... 6-2
General Checks ........................................................... 6-5
Checking the Engine Oil .............................................. 6-6
Changing the Engine Oil and Filter ..........................6-10
Checking and Changing the Engine Coolant ........... 6-11
Spark Plugs ................................................................ 6-14
Changing the Air Cleaner Filter ................................ 6-15
Checking the Transmission Oil (Manual) .................. 6-18
Checking the Transmission Fluid (Automatic) .......... 6-20
Checking the Brakes ................................................. 6-22
Checking the Clutch Fluid ......................................... 6-24
Air Conditioning Care ................................................ 6-24
Changing the Air Conditioner Filter .......................... 6-26
Checking Drive Belts ................................................. 6-29
Checking and Replacing Fuses ................................ 6-30
Checking The Battery ................................................ 6-32
Checking The Eclectric Cooling Fans ....................... 6-34
Power Steering Fluid Level ....................................... 6-34
Fuel Filter ................................................................... 6-35
Replacement of Headlight Bulbs ............................... 6-39
Headlight Aiming Adjustment .................................... 6-40
Bulb Wattages ............................................................ 6-43
Fuse Panel Description ............................................. 6-44
DO-IT-YOURSELF MAINTENANCE
6
6

6
DO-IT-YOURSELF MAINTENANCE
5GENERAL CHECKS
G020A01HP-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 Engine coolant hose condition
o Fluid leaks
(on or below components)
o Power steering fluid level
o Battery condition
o Air filter condition G020B01A-AAT
Vehicle Exterior
The following should be checked
monthly:
o Overall appearance and condition
o Wheel condition and wheel nut
torque
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and body corrosion
o Fluid leaks
o Door and hood lock condition
o Tire pressure and condition (including spare tire) o Defroster, heating system opera-
tion (and air conditioning, if in- stalled)
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 Sun visor operation If you notice anything that does not operate correctly or appears to be functioning incorrectly, inspect it care- fully and seek assistance from yourHyundai dealer if service is needed.
G020C01HP-GAT
Vehicle Interior
The following should be checked each
time when the vehicle is driven:
o Lights operation
o Windshield wiper operation
o Horn operation

6 DO-IT-YOURSELF MAINTENANCE
10CHANGING THE ENGINE OIL AND FILTER
!
The engine oil and filter should be changed at those intervals specified in the maintenance schedule in Sec- tion 5. If the car is being driven in severe conditions, more frequent oiland filter changes are required. The procedure for changing the oil and filter is as follows:
1. Park the car on level ground and set the parking brake. Start the engine and let it warm up until the needle on the coolant temperature gauge moves above the lowestmark. Turn the engine off and place the gear selector lever in "P" (auto- WARNING:
Be very careful when draining the engine oil as it may be hot enough to burn you!
4. When the oil has stopped draining, replace the drain plug using a new gasket and retighten by turning itclockwise. Oil pan drain plug tightening torque: 3.5 ~ 4.5 kgf.m
G040A03HP-GAT
HHP5004
G040A01HP
G040A02HP matic transmission) or reverse gear (manual transmission).
2. Open the hood and remove the engine oil filler cap.
3. Slide underneath the car and loosen the drain plug by turning it counter-clockwise with a wrench of theproper size. Be sure that a drain pan is in position to catch the oil as it drains out, then remove the drainplug.
Diesel Engine (2.9 CRDi)
Diesel Engine (2.5 TCI)
Gasoline Engine
Oil filter
Drain plug Oil filler cap
Oil filler cap
Oil filter
Drain plug Oil filler cap
Oil filter
Drain plug

6 DO-IT-YOURSELF MAINTENANCE
18
!
CHECKING THE TRANSMIS- SION OIL (MANUAL)FILLING THE WASHER RES- ERVOIR
CAUTION:
o Radiator antifreeze (engine cool- ant) should not be used in the washer system because it will damage the car's finish.
o The washer should not be oper- ated if the washer reservoir isempty. This can damage the washer fluid pump.
! G100A04HP-GAT Transmission lubricant in the manual transmission should be checked at those intervals specified in the ve-hicle maintenance schedule in Sec- tion 5.
Recommended Oil Use only HYUNDAI GENUINE PARTS MTF 75W/85 (API GL-4) in the manual transmission. Drain plug
G090A02HP-AAT The washer fluid reservoir supplies fluid to the windshield washer sys- tem. A good quality washer fluid should be used to fill the washer reservoir. The fluid level should be checked morefrequently during inclement weather or whenever the washer system is in more frequent use. The capacity of the washer reservoir is 4.5 liters. HHP5017
HHP5010
Filler plug
WARNING:
o Windshield washer fluid agents contain some amounts of alco- hol and can be flammable undercertain circumstances. Do not allow sparks or flame to contact the washer fluid or the washerfluid reservoir. Damage to the vehicle or its occupants could occur.
o Windshield washer fluid is poi- sonous to humans and animals.Do not drink windshield washer fluid. Serious injury or death could occur.