2005 HYUNDAI TUCSON water pump

1
FEATURES OF YOUR HYUNDAI
49
B330A03A-AATTACHOMETERThe tachometer registers the speed of your
engine in revolutions per minute (rpm).
CAUTION:
The engine should not be raced to such a
speed that the needle enters the red zone
on the tachometer face. This can cause
severe engine damage and may void your
warranty.
!
B300A01A-AATSPEEDOMETERYour Hyundai's speedometer is calibrated in
miles per hour (on the outer scale) and kilome-
ters per hour (on the inner scale). The needle on the engine coolant temperature
gauge should stay in the normal range. If it moves
across the dial to "H" (HOT), pull over and stop as
soon as possible and turn off the engine. Then
open the hood and, after the engine has cooled,
check the coolant level and the water pump drive
belt. If you suspect cooling system trouble, have
your cooling system checked by a Hyundai dealer
as soon as possible.
B300A01JM B330A01JM

2
DRIVING YOUR HYUNDAI
21
C160D01A-AATCheck Battery and CablesWinter puts additional burdens on the battery
system. Visually inspect the battery and cables
as described in Section 6. The level of charge
in your battery can be checked by your Hyundai
dealer or a service station.C160C01A-AATUse High Quality Ethylene Glycol
CoolantYour Hyundai is delivered with high quality
ethylene glycol coolant in the cooling system. It
is the only type of coolant that should be used
because it helps prevent corrosion in the cool-
ing system, lubricates the water pump and
prevents freezing. Be sure to replace or replen-
ish your coolant in accordance with the main-
tenance schedule in Section 5. Before winter,
have your coolant tested to assure that its
freezing point is sufficient for the temperatures
anticipated during the winter.NOTE:o Tire chains are not legal in all states.
Check state laws before fitting tire
chains.
o Tire chains are to be used on front tires
only.
C160A01A-AATThe more severe weather conditions of winter
result in greater wear and other problems. To
minimize the problems of winter driving, you
should follow these suggestions:C160B01JM-AATSnowy or Icy ConditionsTo drive your vehicle in deep snow, it may be
necessary to use snow tires or to install tire
chains on your tires. If snow tires are needed,
it is necessary to select tires equivalent in size
and type of the original equipment tires. Failure
to do so may adversely affect the safety and
handling of your car. Furthermore, speeding,
rapid acceleration, sudden brake applications,
and sharp turns are potentially very hazardous
practices.
During deceleration, use engine braking to the
fullest extent. Sudden brake applications on
snowy or icy roads may cause skids to occur.
You need to keep sufficient distance between
the vehicle in operation in front and your vehicle.
Also, apply the brake gently. It should be noted
that installing tire chains on the tire will provide
a greater driving force, but will not prevent side
skids.WINTER DRIVING
C160F01A-AATCheck Spark Plugs and Ignition
SystemInspect your spark plugs as described in Sec-
tion 6 and replace them if necessary. Also
check all ignition wiring and components to be
sure they are not cracked, worn or damaged in
any way.C160E01A-AATChange to "Winter Weight" Oil if
NecessaryIn some climates it is recommended that a lower
viscosity "winter weight" oil be used during cold
weather. See Section 9 for recommendations.
If you aren't sure what weight oil you should use,
consult your Hyundai dealer.

34WHAT TO DO IN AN EMERGENCY
IF THE ENGINE OVERHEATS
!!
!
WARNING:
While the engine is running, keep hair,
hands and clothing away from moving parts
such as the fan and drive belts to prevent
injury.
5. If the water pump drive belt is broken 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 opening and cause seri-
ous burns.6. If you cannot find the cause of the overheat-
ing, wait until the engine temperature has
returned to normal. Then, if coolant has been
lost, carefully add coolant to the reservoir
(page 6-9) to bring the fluid level in the
reservoir up to the halfway mark.
7. Proceed with caution, keeping alert for fur-
ther signs of overheating. If overheating
happens again, call a Hyundai dealer for
assistance.
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 Hyundai
dealer.
D030A02A-AATIf your temperature gauge indicates overheat-
ing, you experience a loss of power, or hear loud
pinging or knocking, the engine is probably too
hot. If this happens, 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" (auto-
matic), or neutral (manual transaxle) and set
the parking brake. If the air conditioning is on,
turn it off.
3. If engine coolant is running out under the car
or steam is coming out from the hood, stop
the engine. Do not open the hood until the
coolant has stopped running or the steaming
has stopped. If there is no visible loss of
engine coolant and no steam, leave the
engine running and check to be sure the
engine cooling fan is operating. If the fan is
not running, turn the engine off.
4. Check to see if the water pump drive belt is
missing. If it is not missing, check to see that
it is tight. If the drive belt seems to be
satisfactory, check for coolant leaking from
the radiator, hoses or under the car. (If the
air conditioning had been in use, it is normal
for cold water to be draining from it when you
stop).

5
VEHICLE MAINTENANCE REQUIREMENTS
5
Note : (1) When replace drive belt and inspect water pump.
(2) For every 48 months or 37,200 miles (60,000 km), whichever occurs first : "I"
For every 72 months or 56,000 miles (90,000 km), whichever occurs first : "R"
(3) Inspect every 25,000 miles (40,000 km)and replace every 62,000 miles (100,000 km).
(4) lnspect every 25,000 miles (40,000 km)
(5) For every 12 months or 12,500 miles (20,000 km) whichever occurs first :"R"F030C02JM-AATR : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
GENERAL ITEMS
DRIVE BELT
COOLANT
TIMING BELT (WHEN REPLACE TIMING BELT AND INSPECT
WATER PUMP : 2.7L) (See Note (2)- 2.0 L)
MANUAL TRANSAXLE OIL
AUTOMATIC TRANSAXLE FLUID
BRAKE FLUID
BRAKE HOSES AND LINES
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
POWER STEERING PUMP, BELT AND HOSES
DRIVESHAFTS AND BOOTS
AIR CONDITIONING REFRIGERANT
TRANSFER CASE OIL (4WD)
REAR AXLE OIL (4WD)
PROPELLAR SHAFT CLEAN, BOLT RETIGHTEN (4WD)
AIR CONDITIONER FILTER 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19 No. DESCRIPTIONMILES X 1000
KILOMETERS X 1000
MONTHS
2.0 DOHC (ALT, W/PUMP) See Note (1)
2.7 V6 (ALT, P/STR'G, A/CON)7.5
12
6
I15
24
12
I
I
I
I
I
I
I
I
I
I22.5
36
18
I30
48
24
I
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I37.5
60
30
I45
72
36
I
I
I
I
I
I
I
I
I
I52.5
84
42
I60
96
48
I
I
R
R
I
I
I
I
I
I
I
I
I
I
I
I
I67.5
108
54
I75
120
60
I
I
I
I
I
I
I
I
I
I82.5
132
66
I90
144
72
I
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I97.5
156
78
I105
168
84
I
R
I
I
I
I
I
I
I
I112.5
180
90
I120
192
96
I
I
R
R
I
I
I
I
I
I
I
I
I
I
I
I
I127.5
204
102
I135
216
108
I
I
I
I
I
I
I
I
I
I142.5
228
114
I150
240
120
I
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I See Note (3)
See Note (4)
See Note (5)

5
VEHICLE MAINTENANCE REQUIREMENTS6
MAINTENANCE UNDER SEVERE USAGE CONDITIONS
SEVERE DRIVING CONDITIONSA - Repeatly driving short distance of less than 5miles(8km) in normal tempera
ture or less than 10miles(16km) 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 weatherF040A02JM-AATThe 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
*1. Transfer case Oil ended Rear Axle Oil should be changed anytime they have been submerged in water.
E - Driving in sandy areas
F - Driving in heavy traffic area over 90°F(32°C)
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 100 MPH(170 Km/h)
K - Frequently driving in stop-and-go conditionsENGINE OIL AND FILTER
TIMING BELT
(WHEN REPLA CE TIMING BELT and INSPECT WATER PUMP : 2.7L)
AIR CLEANER FILTER
SPARK PLUGS
BRAKE PADS, CALIPERS AND ROTORS
REAR BRAKE DRUMS/LININGS/PADS, PARKING BRAKE
STEERING GEAR BOX, LINKAGE & BOOTS/
LOWER ARM BALL JOINT
DRIVESHAFTS AND BOOTS
MANUAL TRANSAXLE OIL
AUTOMATIC TRANSAXLE FLUID
AIR CONDITIONER FILTER
TRANSFER CASE OIL (4WD) *
1
REAR AXLE OIL (4WD) *
1
MAINTENANCE ITEM
R
I/R
R
R
I
I
I
I
R
R
R
R
R
EVERY 3,000 MILES (4,800 KM) OR 3 MONTHS
INSPECT EVERY 20,000MILES (32,200 KM)
REPLACE EVERY 40,000MILES (64,400 KM)
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
EVERY 7,500 MILES (12,000 KM) OR 6 MONTHS
EVERY 60,000 MILES (96,000 KM)
EVERY 30,000 MILES (48,000 KM)
MORE FREQUENTLY
EVERY 25,000 MILES (40,000 KM)
EVERY 50,000 MILES (80,000 KM)
DRIVING
CONDITION MAINTENANCE
INTERVALS MAINTENANCE
OPERATION
A, B, C, F, G, H, I, K
C, D, F, G
C, E
B, H
C, D, G, H
C, D, G, H
C, D, E, F, G
C, E, F
A, C, D, E, F, G, H, I, J
A, C, E, F, G, H, I
C, E,
C, E, G, I
C, E, G, I

6
DO-IT-YOURSELF MAINTENANCE
12
G090A01JM
FILLING THE WASHER RESERVOIRG090A01JM-AATThe washer fluid reservoir supplies fluid to the
front and rear washer systems.
A good quality washer fluid should be used to fill
the washer reservoir. The fluid level should be
checked more frequently during inclement
weather or whenever the washer system is in
more frequent use.
The capacity of the washer reservoir is 3.59
U.S. quarts (3.4 Liters).
CAUTION:
o Radiator anti-freeze (engine coolant)
should not be used in the washer system
because it will damage the car's finish.
o The washer should not be operated if the
washer reservoir is empty. This can dam-
age the washer fluid pump.
!
WINDSHIELD WIPER BLADESG080A02A-AATThe wiper blades should be carefully inspected
from time to time and cleaned to remove accu-
mulations of road film or other debris. To clean
the wiper blades and arms, use a clean sponge
or cloth with a mild soap or detergent and water.
If the wipers continue to streak or smear the
glass, replace them with genuine Hyundai re-
placement parts or their equivalent.
!
CAUTION:
o Do not operate the wipers on dry glass.
This can result in more rapid wear of the
wiper blades and may scratch the glass.
o Keep the blade rubber out of contact
with petroleum products such as engine
oil, gasoline, etc.
HJM5032

6
DO-IT-YOURSELF MAINTENANCE
17
!
G130B02A-AATTo Replace the FluidRecommended brake fluid conforming to DOT
3 or DOT 4 specification should be used. The
reservoir cap must be fully tightened to avoid
contamination from foreign matter or moisture.NOTE:Do not allow any other liquids to contami-
nate the brake fluid. Seal damage will result.
WARNING:
Use caution when handling brake fluid. It
can damage your vision if you get it in your
eyes. It will also damage your vehicle's
paint if spilled on it and not removed imme-
diately.
G190A01GK
DOHC CVVT V6
Water Pump Pulley
0.2~0.24 in.
(5~6 mm)
Power steering
COMP
Auto
tensioner
Alternator Pulley
Crankshaft PulleyAlternator
Eng.pulley
AIR CONDITIONING CARE
G140D02A-AATChecking the Compressor Drive Belt
!
G140A01A-AATKeeping the Condenser CleanThe air conditioning condenser (and engine
radiator) should be checked periodically for
accumulation of dirt, dead insects, leaves, etc.
These can interfere with maximum cooling ef-
ficiency. When removing such accumulations,
brush or hose them away carefully to avoid
bending the cooling fans.
G140C01A-AATLubricationTo lubricate the compressor and the seals in the
system, the air conditioning should be run for at
least 10 minutes each week. This is particularly
important during cool weather when the air
conditioning system is not otherwise in use.
G140B01A-AATChecking the Air Conditioning Opera-
tion1. Start the engine and let it run at a fast idle for
several minutes with the air conditioning set
at the maximum cold setting.
2. If the air coming out of the in-dash vents is
not cold, have the air conditioning system
inspected by your Hyundai dealer.
CAUTION:
Running the air conditioning system for
extended periods of time with a low refrig-
erant level may damage the compressor.

6
DO-IT-YOURSELF MAINTENANCE
21
G190A01GK
DOHC CVVT V6
Water Pump Pulley
0.2~0.24 in.
(5~6 mm)
Power steering
COMP
Auto
tensioner
Alternator Pulley
Crankshaft PulleyAlternator
Eng.pulley
CHECKING DRIVE BELTSDrive belts should be checked periodically for
proper tension and adjusted if necessary. At the
same time, belts should be examined for cracks,
wear, fraying or other evidence of deterioration
and replaced if necessary.
Belt routing should also be checked to be sure
there is no interference between the belts and
other parts of the engine. After a belt is replaced,
the new belt should be adjusted again after two
or three weeks to eliminate slack resulting from
initial stretching after use.G190A01A-AAT
CHECKING AND REPLACING
FUSES
!
G200B01JM-AATReplacing Accessory FusesCAUTION:When replacing a fusible link, never use
anything but a new fusible link with the
same or lower amperage rating. Never use
a piece of wire or a higher-rated fusible link.
This could result in serious damage and
create a fire hazard.
The fuse box for the lights and other electrical
accessories will be found on the left side of
crash pad. Inside the box you will find a list
showing the circuits protected by each fuse.
If any of your car's lights or other electrical
G200A03A-AATReplacing a Fusible LinkA fusible link will melt if the electrical circuits from
the battery are ever overloaded, thus prevent-
ing damage to the entire wiring harness. (This
could be caused by a short in the system
drawing too much current.) If this ever happens,
have a Hyundai dealer determine the cause,
repair the system and replace the fusible link.
The fusible links are located in a relay box in the
engine compartement for easy inspection.
HJM4002
G200A01JM
Open-
ReplaceGood