Hyundai H-100 Truck (2012 year). Instruction — part 9

5 VEHICLE MAINTENANCE REQUIREMENTS

SCHEDULED MAINTENANCE

F030A01HR-GAT

Except European Community

The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for

all vehicle services to protect your warranty. Where both kilometers and time are shown, the frequency of service is

determined by whichever occurs first.

F030D02HR-GAT

R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary

KILOMETERS X 1000

NO.

DESCRIPTION

MONTHS

ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL)

ENGINE OIL AND FILTER

See Note(1), (2)

AIR CLEANER FILTER

See Note(3)

FUEL FILTER*

VALVE CLEARANCE (For 2.6 N/A, 2.5 TCI)

INJECTION TIMING (IF EXHAUST GAS INCLUDES BLACK SMOKE)

EGR SYSTEM (VALVE, TUBE, HOSE)

TIMING BELT (For 2.6 N/A, 2.5 TCI)

DRIVE BELT (FOR WATER PUMP AND ALTERNATOR)

ENGINE IDLE SPEED

FUEL SYSTEM LEAKS

See Note(4)

INJECTION NOZZLE (IF EXHAUST GAS INCLUDES BLACK SMOKE)

VACUUM PUMP AND VACUUM HOSE

See Note(5)

VACUUM PUMP OIL HOSE

See Note(5)

Note :

(1)2.6 N/A, 2.5 TCI : For every 5,000 KM or 6 months, whichever occurs first : "R"

A2.5 : For every 10,000 KM or 6 months, whichever occurs first : "R"

(2) Republic of South Africa (If the vehicle is lubricated API CH-4 grade or above.):

For every 7,500 KM or 6 months, whichever occurs first : "R"

(3) For China, India and Middle East : For every 15,000 KM or 12 months, whichever occurs first : "R"

Except China, India and Middle East : For every 45,000 KM or 36 months, whichever occurs first : "R"

(4) Inspect every day.

(5) For every 15,000 KM or 12 months, whichever occurs first : "I"

VEHICLE MAINTENANCE REQUIREMENTS

F030C06HR-GAT

R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary

KILOMETERS X 1000

NO.

DESCRIPTION

MONTHS

GENERAL MAINTENANCE

COOLANT

See Note (1), (2), (3)

MANUAL TRANSMISSION OIL

REAR AXLE OIL

CLUTCH / BRAKE PEDAL FREE-PLAY

See Note (4)

BRAKE OIL RESERVOIR

BRAKE HYDRAULIC FLUID

FRONT BRAKE PADS

FRONT BRAKE CALIPERS / CYLINDERS / DISC

REAR BRAKE DRUMS / LININGS / CYLINDERS

PARKING BRAKE

TIRE CONDITION / PRESSURE

EXHAUST SYSTEM / MOUNTING

STEERING JOINT / RACK / BOX OIL LEAKS

SUSPENSION JOINT / SEALS

FRONT WHEEL BEARING

COOLANT HOSES

BRAKE PIPE CORROSION

CLIMATE CONTROL AIR FILTER

See Note (5)

AIR CONDITIONING REFRIGERANT

POWER STEERING PUMP AND HOSES

Note : (1) At first, replace at 48,000 km (30,000 miles) or 24 months: after that, replace every 40,000 km (25,000 miles) or 24 months.

(2) When adding coolant, use only a qualified coolant additive for your vehicle and never mix hard water in the coolant filled

at the factory. An improper coolant mixture can result in serious malfunction or engine damage.

(3) For your convenience, it can be replaced prior to it's interval when you do maintenance of other items.

(4) Inspect every day.

(5) Clean it every 10,000 km or 6 month or more frequently.

5 VEHICLE MAINTENANCE REQUIREMENTS

F040A01HR-GAT

For European Community Only

The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for

all vehicle services to protect your warranty. Where both kilometers and time are shown, the frequency of service is

determined by whichever occurs first.

F040D03HR-GAT

R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary

KILOMETERS X 1000

7.5

NO.

DESCRIPTION

MONTHS

ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL)

ENGINE OIL AND FILTER

See Note (1)

AIR CLEANER FILTER

FUEL SYSTEM LEAKS

See Note (2)

FUEL FILTER*

See Note (3), (4)

VALVE CLEARANCE

See Note (5)

EGR SYSTEM (VALVE, TUBE, HOSE)

INJECTION TIMING (IF EXHAUST GAS INCLUDES BLACK SMOKE)

TIMING BELT

DRIVE BELT (FOR WATER PUMP/ALTERNATOR)

ENGINE IDLE SPEED

INJECTION NOZZLE (IF EXHAUST GAS INCLUDES BLACK SMOKE)

VACUUM PUMP AND VACUUM HOSE

VACUUM PUMP OIL HOSE

Note :

(1) For every 7,500 KM or 6 months, whichever occurs first : "R"

(2) Inspect every day.

(3) Inspect every 30,000 km or 18 months; replace every 60,000 km or 36 months

(4) This interval depends on fuel quality. It is applicable only when using a qualified fuel, "EN 590 or equivalent". If the diesel fuel specifications

don't meet the European standards EN590, replace it more frequently. Consult an authorized HYUNDAI dealer for details. In case of

low engine power or fuel pressure decrease of the fuel filter, replace fuel filter immediately regardless of maintenance schedule.

(5) For every 20,000 KM : "I"

VEHICLE MAINTENANCE REQUIREMENTS

F040C06HR-GAT

R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary

KILOMETERS X 1000

7.5

NO.

DESCRIPTION

MONTHS

GENERAL MAINTENANCE

COOLANT

See Note (1), (2), (3)

MANUAL TRANSMISSION OIL

REAR AXLE OIL

CLUTCH / BRAKE PEDAL FREE-PLAY

See Note (4)

BRAKE OIL RESERVOIR

BRAKE HYDRAULIC FLUID

FRONT BRAKE PAD

FRONT BRAKE CALIPERS/CYLINDERS/DISC

REAR BRAKE DRUMS/LININGS/CYLINDERS

PARKING BRAKE

TIRE CONDITION/PRESSURE

EXHAUST SYSTEM/MOUNTING

STEERING JOINT/RACK/BOX/OIL LEAKS

SUSPENSION JOINT/SEALS

FRONT WHEEL BEARING

COOLANT HOSES

BRAKE PIPE CORROSION

CLIMATE CONTROL AIR FILTER

See Note (5)

AIR CONDITIONING REFRIGERANT

POWER STEERING PUMP AND HOSES

Note: (1) At first, replace at 100,000 km (62,500 miles) or 60 months: after that, replace every 40,000 km (25,000 miles) or 24 months.

(2) When adding coolant, use only a qualified coolant additive for your vehicle and never mix hard water in the coolant filled

at the factory. An improper coolant mixture can result in serious malfunction or engine damage.

(3) For your convenience, it can be replaced prior to it's interval when you do maintenance of other items.

(4) Inspect every day.

(5) Clean it every 10,000 KM or 6 month, or more frequently.

5 VEHICLE MAINTENANCE REQUIREMENTS

MAINTENANCE UNDER SEVERE USAGE CONDITIONS

F050A04HR-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

MAINTENANCE

DRIVING

MAINTENANCE ITEM

MAINTENANCE INTERVALS

OPERATION

CONDITION

2.6 N/A, 2.5TCI

Every 3,000 km or 6 months

Except E.C

Engine oil and filter

A2.5

Every 10,000 km or 6 months

A, B, C, F, H, J

For E.C

Every 4,000 km

Air cleaner filter

More frequently

C, E

Timing belt (For 2.6 N/A, 2.5 TCI)

Every 60,000 km or 48 months

D, E, F, G

Brake pads, calipers, rotors

More frequently

C, D, G, H

Rear brake drums and linings

More frequently

C, D, G, H

2.6 N/A, 2.5TCI

Every 3,000 km or 6 months

C, D, E, F

Steering gear box, linkage & boots

A2.5

More frequently

C, D, E, F, G

Climate control air filter

More frequently

C, E

A, C, D, E, F, G,

Manual transmission oil

Every 120,000 km

H, I, J

Rear axle oil (For A2.5)

Every 90,000 km

C, E, G, H, I, J

Propeller shaft

Every 15,000 km or 12 months

C, E

VEHICLE MAINTENANCE REQUIREMENTS

SEVERE DRIVING CONDITIONS

A-Repeated short distance driving

F-More than 50% driving in heavy city traffic during hot above

B-Extensive idling

32°C (90°F)

C-Driving in dusty conditions

G-Driving in mountainous areas

D-Driving in areas using salt or other corrosive materials

H-Towing a trailer or police car, taxi, or commercial type

or in very cold weather

operation

E-Driving in sandy areas

- Driving for patrol car, taxi, commercial car or vehicle towing

J -Driving over 170 km/h

5 VEHICLE MAINTENANCE REQUIREMENTS

EXPLANATION OF SCHEDULED MAINTENANCE ITEMS

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F060D01TB-GAT

F060C01A-AAT

o Engine Oil and Filter

o Fuel Lines, Fuel Hoses and

o Fuel Filter

Connections

The engine oil and filter should be

A clogged filter can limit the speed at

changed at those intervals specified in

Check the fuel lines, fuel hoses and

which the vehicle may be driven, dam-

the maintenance schedule. If the ve-

connections for leakage and damage.

age the emission system and cause

hicle is being driven in severe condi-

Have a trained technician replace any

hard starting. If an excessive amount

tions, more frequent oil and filter

damaged or leaking parts immediately.

of foreign matter accumulates in the

changes are required.

fuel tank, the filter may require re-

placement more frequently.

After installing a new filter, run the

WARNING:

engine for several minutes, and check

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Never work on injection system with

for leaks at the connections. Fuel fil-

o Valve Clearances

engine running or within 30 sec-

ters should be installed by trained

An incorrect valve clearance will not

onds after shutting off engine. High

technicians.

only result in rough engine operation,

pressure pump, rail, injectors and

but will also cause excessive noise

high pressure pipes are subject to

and reduced engine output.

high pressure even after the engine

Inspect valve clearance and adjust as

stopped. The fuel jet produced by

required while the engine is hot.

fuel leaks may cause serious injury,

if it touch the body. People using

See page 9-4 for the valve clearance

pacemakers should not move than

description.

30cm closer to the ECU or wiring

harness within the engine room

while engine is running, since the

high currents in the Common Rail

system produce considerable mag-

netic fields.

VEHICLE MAINTENANCE REQUIREMENTS

F060F01A-AAT

F060G01A-AAT

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o Vacuum and Crankcase

o Vapor Hose and Fuel Filler Cap

o Drive Belts

Ventilation Hoses

The vapor hose and fuel filler cap

Inspect all drive belts (water pump and

Inspect the surface of hoses for evi-

should be inspected at those intervals

alternator) for evidence of cuts, cracks,

dence of heat and/or mechanical dam-

specified in the maintenance sched-

excessive wear or oiliness, and re-

age. Hard and brittle rubber, cracking,

ule. Make sure that a new vapor hose

place if necessary. Drive belts should

tears, cuts, abrasions, and excessive

or fuel filler cap is correctly replaced.

be checked periodically for proper ten-

swelling indicate deterioration. Particu-

sion and adjusted as necessary.

lar attention should be paid to examin-

F060H01A-AAT

ing those hose surfaces nearest to

o Air Cleaner Filter

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high heat sources, such as the ex-

o Timing Belt

haust manifold.

A Genuine Hyundai air cleaner filter is

Inspect the hose routing to assure that

recommended when the filter is re-

Inspect all parts related with the timing

the hoses do not come in contact with

placed.

belt for damage and deformation. Re-

any heat source, sharp edges or mov-

place any damaged parts immediately.

ing component which might cause heat

F070B01A-GAT

damage or mechanical wear. Inspect

o Cooling System

all hose connections, such as clamps

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and couplings, to make sure they are

Check the cooling system part, such

o Manual Transmission Oil

secure, and that no leaks are present.

as radiator, coolant reservoir, hoses

Inspect the manual transmission oil

Hoses should be replaced immedi-

and connections for leakage and dam-

according to the maintenance sched-

ately if there is any evidence of dete-

age. Replace any damaged parts.

ule.

rioration or damage.

F070C01A-AAT

NOTE:

o Coolant

If the oil level is low, check for

possible leaks before adding oil.

The coolant should be changed at

Do not overfill.

the intervals specified in the mainte-

nance schedule.

5 VEHICLE MAINTENANCE REQUIREMENTS

F070F01A-AAT

F070J01A-AAT

F070M01A-AAT

o Brake Hoses and Lines

o Brake Pads, Calipers and

o Steering Gear Box, Linkage &

Rotors

Boots/Lower arm Ball Joint

Visually check for proper installation,

chafing, cracks, deterioration and any

Check the pads for excessive wear,

With the vehicle stopped and engine

leakage. Replace any deteriorated or

discs for run out and wear, and cali-

off, check for excessive free-play in

damaged parts immediately.

pers for fluid leakage.

the steering wheel. Check the linkage

for bends or damage. Check the dust

boots and ball joints for deterioration,

F070G02A-GAT

cracks, or damage. Replace any dam-

F070K01A-AAT

o Brake Fluid

aged parts.

o Exhaust Pipe and Muffler

Check brake fluid level in the brake

Visually inspect the exhaust pipes,

fluid reservoir. The level should be

muffler and hangers for cracks, dete-

between "MIN" and "MAX" marks on

rioration, or damage. Start the engine

F070N01A-AAT

the side of the reservoir. Use only

and listen carefully for any exhaust

o Power Steering Pump, Belt

hydraulic brake fluid conforming to DOT

gas leakage. Tighten connections or

and Hoses

3 or DOT 4.

replace parts as necessary.

Check the power steering pump and

hoses for leakage and damage. Re-

place any damaged or leaking parts

F070H01A-AAT

F070L01A-AAT

immediately. Inspect the power steer-

o Rear Brake Drums/Linings

o Suspension Mounting Bolts

ing belt for evidence of cuts, cracks,

Parking Brake

excessive wear, oiliness and proper

Check the suspension connections for

Check the rear brake drums and lin-

tension. Replace or adjust it if neces-

looseness or damage. Retighten to the

ings for scoring, burning, leaking fluid,

sary.

specified torque.

broken parts, and excessive wear.

Inspect the parking brake system in-

cluding the parking brake lever and

cables. For detailed service proce-

dures, refer to the Shop Manual.

VEHICLE MAINTENANCE REQUIREMENTS

G080U01P-GAT

o Wheel Bearing Grease

Check the wheel bearings and grease

according to the maintenance sched-

ule. For inspection procedures, see

Shop Manual.

F070Q01A-AAT

o Air Conditioning Refrigerant

Check the air conditioning lines and

connections for leakage and damage.

Check air conditioning performance

according to the relevant shop manual

if necessary.

DO-IT-YOURSELF MAINTENANCE

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 Filter

6-13

Checking the Transmission Oil (Manual)

6-16

Checking the Rear Axle Oil

6-17

Checking the Brakes

6-18

Air Conditioning Care

6-19

Checking the Climate Control Air Filter

(For Evaporator and Blower Unit)

6-20

Checking Drive Belts

6-22

Checking and Replacing Fuses

6-22

Checking the Battery

6-25

Power Steering Fluid Level

6-27

Fuel Filter

6-28

Replacement of Light Bulbs

6-31

Bulb Wattages

6-38

Fuse Panel Description

6-39

6 DO-IT-YOURSELF MAINTENANCE

FRONT OPEN SERVICE PANEL

G010A01HR-GAT

WARNING:

Do not press excessively

or step on the hood.

This can cause the hood to

fall and result in serious

injury.

1. Engine Coolant Reservoir

2. Air Conditioner Filter (If Installed)

3. Windshield Washer Fluid Reservoir Cap

G010A01HR

DO-IT-YOURSELF MAINTENANCE

ENGINE COMPARTMENT

G010B01HR-GAT

Diesel Engine (2.6 N/A)

CAUTION:

To inspect or service the en-

gine, first move the front seat.

(Refer to " To Access the En-

gine" on page 1-12).

G010B01HR

1. Power Steering Fluid Reservoir

3. Engine Oil Level Dipstick

5. Fuse and Relay Box

(If Installed)

4. Fuel Filter

6. Radiator Cap

2. Engine Oil Filler Cap

6 DO-IT-YOURSELF MAINTENANCE

G010C01HR-GAT

Diesel Engine (2.5 TCI)

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 should

handle tools and other

heavy objects carefully so

that the plastic cover of the

engine is not damaged.

HHR5001

1. Power Steering Fluid Reservoir

3. Engine Oil Level Dipstick

5. Fuse and Relay Box

(If Installed)

4. Fuel Filter

6. Radiator Cap

2. Engine Oil Filler Cap

DO-IT-YOURSELF MAINTENANCE

GENERAL CHECKS

G020A01HR-GAT

G020B01A-AAT

G020C01HR-GAT

Engine Compartment

Vehicle Exterior

Vehicle Interior

The following should be checked regu-

The following should be checked

The following should be checked each

larly:

monthly:

time when the vehicle is driven:

o Lights operation

o Engine oil level and condition

o Overall appearance and condition

o Windshield wiper operation

o Transmission fluid level and condi-

o Wheel condition and wheel nut torque

o Horn operation

tion

o Exhaust system condition

o Defroster, heater system operation

o Brake fluid level

o Light condition and operation

(and air conditioning, if installed)

o Engine coolant level

o Windshield glass condition

o Steering operation and condition

o Windshield washer fluid level

o Wiper blade condition

o Mirror condition and operation

o Accessory drive belt condition

o Paint condition and body corrosion

o Turn signal operation

o Engine coolant hose condition

o Fluid leaks

o Accelerator pedal operation

o Fluid leaks (on or below compo-

o Door and hood lock condition

o Brake operation, including parking

nents)

o Tire pressure and condition

brake

o Power steering fluid level

(including spare tire)

o Manual transmission operation, in-

o Battery condition

cluding clutch operation

o Air filter condition

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.

6 DO-IT-YOURSELF MAINTENANCE

CHECKING THE ENGINE OIL

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(2) The engine oil quality should meet

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the following API classification:

To Check the Oil Level

Engine oil is essential to the perfor-

CF-4 or ABOVE

mance and service of the engine. It is

2.6 N/A

(3) The engine oil quality should meet

suggested that you check the oil level

the following ACEA classification :

at least once a week or every 500 km in

B2 or B3

normal use and more often if you are on

a trip or driving in severe conditions.

NOTE:

o For diesel-powered vehicle SAE

G030B02HR-GAT

0W-30 oil should be used only in

Recommended Oil

areas where extremely cold tem-

peratures of 10°C (50°F) or below

(1) Select engine oil of the proper SAE

are experienced.

viscosity number according to the

o For diesel-powered vehicle, if the

atmospheric temperature.

G030C01HR

atmospheric temperatures are 0°C

Recommended viscosity is given in

(32°F) or below, SAE 30 oil must

2.5 TCI

the following illustration.

not be used. This oil should be

used only in areas where the at-

mospheric temperatures are

0°C(32°F) or above.

HHR5003

G030B01HR

DO-IT-YOURSELF MAINTENANCE

Before checking the oil, warm up the

G030D01HR-GAT

If the oil level is close to or below the "L"

engine to normal operating tempera-

Adding Oil

mark, add oil until it reaches the "F"

ture and be sure your car is parked on

mark. To add oil:

2.6 N/A

level ground. Turn the engine off.

1. Remove the oil filler cap by turning

Wait about ten minutes, then remove

it counterclockwise.

the dipstick, wipe it off, fully reinsert the

2. Add oil, then check the level again.

dipstick and withdraw it again. Then

Do not overfill.

note the highest level the oil has reached

3. Replace the cap by turning it clock-

on the dipstick. It should be between

wise.

the upper ("F") and lower ("L") range.

The distance between the "F" and "L"

marks is equal to about 1.5 liters of oil.

G030D01HR

G350A01A-GAT

2.5 TCI

ENGINE OIL CONSUMPTION

Function of Engine Oil

Engine oil has the primary function of

lubricating and cooling the inside of the

engine.

Engine oil consumption

It is normal that an engine should

consume some engine oil while nor-

mal driving. The cause of oil consump-

tion in a normal engine are as follows;

HHR5005

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Hyundai H-100 Truck (2012 year). Instruction — part 9

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