2011 Hyundai H-100 Truck steering

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VEHICLE MAINTENANCE REQUIREMENTS
11
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-GAT
o Brake Fluid
Check brake fluid level in the brake fluid reservoir. The level should be between "MIN" and "MAX" marks on the side of the reservoir. Use only hydraulic brake fluid conforming to DOT3 or DOT 4.
F070L01A-AAT
o Suspension Mounting Bolts
Check the suspension connections for
looseness or damage. Retighten to thespecified torque. F070M01A-AAT
o Steering Gear Box, Linkage &
Boots/Lower arm Ball Joint
With the vehicle stopped and engine off, check for excessive free-play in the steering wheel. Check the linkage for bends or damage. Check the dustboots and ball joints for deterioration, cracks, or damage. Replace any dam- aged parts. F070N01A-AAT
o Power Steering Pump, Belt and Hoses
Check the power steering pump and hoses for leakage and damage. Re-place any damaged or leaking parts immediately. Inspect the power steer- ing belt for evidence of cuts, cracks,excessive wear, oiliness and proper tension. Replace or adjust it if neces- sary.
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.
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. Inspect the parking brake system in- cluding the parking brake lever andcables. For detailed service proce- dures, refer to the Shop Manual.

Front Open Service Panel ............................................ 6-2
Engine Compartment .................................................... 6-3
General Checks ........................................................... 6-5
Checking the Engine Oil ............................................... 6-6
Changing the Oil and Filter ........................................... 6-8
Checking and Changing the Engine Coolant ...............6-10
Changing the Air Cleaner Filte r ....................................6-12
Checking the Transmission Oil (Manual) ....................6-15
Checking the Rear Axle Oil......................................... 6-16
Checking the B rakes ................................................... 6-17
Air Conditioning Care ................................................... 6-18
Checking the Climate Control Air Filter
(For Evaporator and Blower U nit) .............................6-19
Checking Drive Belts................................................... 6-21
Checking and Replacing Fuses .................................. 6-22
Checking the Battery ................................................... 6-24
Power Steering Fluid Level .......................................... 6-26
Fuel Fil ter ..................................................................... 6-27
Replacement of Light Bulbs ......................................... 6-30
Bulb Wattages ............................................................. 6-37
Fuse Panel Description ............................................... 6-38
DO-IT-YOURSELF MAINTENANCE
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DO-IT-YOURSELF MAINTENANCE
3ENGINE COMPARTMENT
1. Power Steering Fluid Reservoir (If Installed)
2. Engine Oil Filler Cap 3. Engine Oil Level Dipstick
4. Fuel Filter
G010B01HR-GAT Diesel Engine (2.6 N/A)
G010B01HR
5. Fuse and Relay Box
6. Radiator CapCAUTION:
To inspect or service the en-gine, first move the front seat.(Refer to " To Access the En- gine" on page 1-12).
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6 DO-IT-YOURSELF MAINTENANCE
4
G010C01HR-GAT Diesel Engine (2.5 TCI)
HHR5001
1. Power Steering Fluid Reservoir (If Installed)
2. Engine Oil Filler Cap 3. Engine Oil Level Dipstick
4. Fuel Filter CAUTION:
o To inspect or service the engine, first move the front seat. (Refer to " To Access the Engine" on page 1-12).
o When inspecting or servic- ing the engine, you shouldhandle tools and other heavy objects carefully so that the plastic cover of theengine is not damaged.
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5. Fuse and Relay Box
6. Radiator Cap

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DO-IT-YOURSELF MAINTENANCE
5
G020A01HR-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 Engine coolant level
o Windshield washer fluid level
o Accessory drive belt condition
o Engine coolant hose condition
o Fluid leaks (on or below compo- nents)
o Power steering fluid level
o Battery condition
o Air filter condition G020C01HR-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
o Defroster, heater system operation
(and air conditioning, if installed)
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 Seat control condition and operation
o Seat belt condition and operation
o Sunvisor operation If you notice anything that does not operate correctly or appears to be functioning incorrectly, inspect it care-fully and seek assistance from your Hyundai dealer if service is needed.
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)
GENERAL CHECKS

6 DO-IT-YOURSELF MAINTENANCE
20
G160A01A-GAT CLUTCH PEDAL
G160A01HR
6 ~ 13 mm (0.24 ~ 0.51 in.)
With the engine off, press lightly on the clutch pedal until you feel a change inresistance. This is the clutch pedal free-play. The free-play should be within the limits specified in the illustration. Ifit is not, have it inspected by your Hyundai dealer and adjusted or re- paired if necessary.
CHECKING THE FREE-PLAY
G150A01A-GAT STEERING WHEEL To check the steering wheel free-play, stop the car with the wheels pointed straight ahead and gently move thesteering wheel back and forth. Use very light finger pressure and be sen- sitive to changes in resistance thatmark the limits of the freeplay. If the free-play is greater than specified, have it inspected by your Hyundai dealerand adjusted or repaired if necessary. HHR5023
30 mm (1.18 in.)
NOTE:
o If you clean the filter with water,
dry it in the open air.
o When cleaning the filter, be care- ful that the filter doesn’t drop or bump against other objects, or damage may result.

6
DO-IT-YOURSELF MAINTENANCE
21
G170A01A-GAT BRAKE PEDAL
G160A01HR
3 ~ 8 mm (0.12 ~ 0.31 in.)
With the engine off, press down on the brake pedal several times to reduce thevacuum in the brake booster. Then, using your hand, press down slowly on the brake pedal until you feela change in resistance. This is the brake pedal free-play. The free-play should be within the limitsspecified in the illustration. If it is not, have it inspected by your Hyundai dealer and adjusted or repaired if nec-essary.
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2
3
CHECKING DRIVE BELTS
Water pump pulley
G190A01HR-GAT
G190A01HR
Drive belts should be checked periodi- cally for proper tension and adjusted ifnecessary. Power steering pulley
Crankshaft pulley
Generator pulley Tension pulley
COMP. pulley
1
2 3
a new belt a used beltProper tension
7 ~ 10 mm9 ~ 12 mm11 ~ 14 mm7 ~ 10 mm
Belt
At the same time, belts should be examined for cracks, wear, fraying or other evidence of deterioration and re-placed if necessary.
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Belt routing should also be checked to be sure there is no interference be-tween the belts and other parts of the engine. After a belt is replaced, the new belt should be adjusted again after twoor three weeks to eliminate slack result- ing from initial stretching after use. WARNING:
The drive belt should be checked when the engine is cool or cold to avoid burning yourself on hot en- gine.

6 DO-IT-YOURSELF MAINTENANCE
26POWER STEERING FLUID LEVEL
G230A03A-GAT The power steering fluid level should be checked regularly. To check the power steering fluid level, be sure the ignition is "OFF", thencheck to make certain that the power steering fluid level is between the "MAX" and "MIN" level markings on the fluidreservoir. NOTE: Grinding noise from the power steer- ing pump may be heard immediatelyafter the engine is started in extremely cold conditions (below - 20°C). If the noise stops during warm up, there isno abnormal function in the system. HHR5014CHECKING ELECTRIC COOLING FANS
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G220B01A-AAT Checking Engine Cooling Fan The engine cooling fan should come on automatically if the engine coolant tem- perature is high. G220C01TB-GAT Checking Condenser Cooling Fan When the air conditioning is in opera- tion, the condenser cooling fan comeson automatically to be controlled by ECU.
G220A01A-AAT
WARNING:
The cooling fan is controlled by en- gine coolant temperature and may sometimes operate even when the engine is not running. Use extremecaution when working near the blades of the cooling fan, so that you are not injured by a rotating fanblade. As the engine coolant temper- ature decreases the fan will automat- ically shut off. This is a normal con-dition.
o When lifting a plastic-cased bat- tery, excessive pressure on the case may cause battery acid toleak, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners.
o Never attempt to charge the bat- tery when the battery cables areconnected.
o The electrical ignition system works with high voltage.Never touch these componentswith the engine running or the ignition switched on.