Get VEHICLE MAINTENANCE REQUIREMENTS Guide for Hyundai Tucson SUV First Generation (2004-2009)

Maintenance Intervals .................................................. 5-2

Scheduled Maintenance ............................................... 5-4

Maintenance Under Severe Usage Conditions ............ 5-7

Explanation of Scheduled Maintenance Items .............. 5-8

VEHICLE MAINTENANCE REQUIREMENTS

MAINTENANCE INTERVALS

F010C01A-GAT

Specified Scheduled Procedures

These are the procedures such as

inspections, adjustments and replace-

ments that are listed in the mainte-

nance charts starting on page 5-4.

These procedures must be performed

at the intervals shown in the mainte-

nance schedule to assure that your

warranty remains in effect. Although it

is strongly recommended that they be

performed by the factory-trained or

distributor-trained technicians at your

Hyundai dealer, these procedures may

be performed at any qualified service

facility.

F010D01A-AAT

General Checks

These are the regular checks you

should perform when you drive your

Hyundai or you fill the fuel tank. A list

of these items will be found on page 6-

F010A01A-GAT

Service Requirements

To assure that you receive the great-

est number of kilometers of satisfying

operation from your Hyundai, certain

maintenance procedures must be per-

formed. Although careful design and

engineering have reduced these to a

minimum, those that are required are

of the utmost importance.

It is your responsibility to have these

maintenance procedures performed to

comply with the terms of the warran-

ties covering your new Hyundai. The

Service Passport supplied with your

new vehicle provides further informa-

tion about these warranties.

F010B01A-AAT

Maintenance Requirements

The maintenance required for your

Hyundai can be divided into three main

areas:

o Specified scheduled procedures

o General checks

o Do-it-yourself maintenance

It is suggested that genuine Hyundai

service parts be used for any required

repairs or replacements. Other parts of

equivalent quality such as engine oil,

engine coolant, manual or auto

transaxle oil, brake fluid and so on

which are not supplied by Hyundai

Motor Company or its distributor may

be used without affecting your war-

ranty coverage but you should always

be sure these are equivalent to the

quality of the original Hyundai parts.

Your Service Passport provides fur-

ther information about your warranty

coverage.

VEHICLE MAINTENANCE REQUIREMENTS

SCHEDULED MAINTENANCE

REQUIREMENTS

F010E01A-AAT

Do-It-Yourself Maintenance

If you are mechanically inclined, own a

few tools that are required and want to

take the time to do so, you can inspect

and service a number of items. For

more information about doing it your-

self, see Section 6.

F010F01A-GAT

A Few Tips

Whenever you have your Hyundai ser-

viced, keep copies of the service

records in your glovebox. This will help

ensure that you can document that the

required procedures have been per-

formed to keep your warranties in ef-

fect. This is especially important when

service is not performed by an autho-

rized Hyundai dealer.

F020A01Y-GAT

Inspection should be performed any

time a malfunction is experienced or

suspected. Receipts for all emission

control system services should be re-

tained to demonstrate compliance with

conditions of the emissions system

warranty.

For severe usage maintenance require-

ments, see page 5-7 of this section.

VEHICLE MAINTENANCE REQUIREMENTS

DESCRIPTION

ENGINE CONTROL SYSTEM MAINTENANCE (GASOLINE)

ENGINE OIL & FILTER For Middle East

Except Middle East

DRIVE 2.0 DOHC (ALTERNATOR, WATER PUMP, P/STR'G) See Note (2)

BELT 2.7 V6 (AUTO-TENSIONER, ALTERNATOR, P/STR'G, A/CON)

FUEL FILTER (MPI TYPE) European Community only

See Note (3) Except European Community

FUEL LINES, FUEL HOSES & CONNECTIONS

TIMING BELT (WHEN REPLACE TIMING BELT AND INSPECT WATER PUMP: 2.7 GSL)

VAPOR HOSE & FUEL FILLER CAP

VACUUM & CRANKCASE VENTILATION HOSES

AIR CLEANER FILTER

AIR CLEANER FILTER For Middle East

FUEL TANK AIR FILTER

SPARK PLUGS

SPARK PLUGS (PLATINUM COATED)

SPARK PLUGS (IRIDIUM COATED)

VALVE CLEARANCE (2.0 GASOLINE ENGINE)

NO.

F030A01A-GAT

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 kilometrage and time are shown, the frequency of service is

determined by whichever occurs first.

F030B05JM-GAT

R :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace of necessary.

105

120

KILOMETERS X 1000

MONTHS

NOTE: (1) Driving in summer season temperature over 40°C (104°F - SAUDI, UAE, OMAN, KUWAIT, BAHRAIN, QATAR, IRAN,

YEMEN ETC) or driving over 170 km/h must conform the severe driving condition.

(2) When replace drive belt and inspect water pump

(3) In case of hard starting or abnormal fuel pressure, replace the fuel filter immediately regardless of maintenance schedule.

(4) For every 90,000km or 48 months : "I"

SCHEDULED MAINTENANCE

R: 40,000km

R: 100,000km

R: 160,000km/120months

See Note (4)

Replace every 10,000 km or 12 months See Note (1)

VEHICLE MAINTENANCE REQUIREMENTS

NO.

DESCRIPTION

ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL)

ENGINE OIL & FILTER See Note (1)

AIR CLEANER FILTER

FUEL FILTER CARTRIDGE European Community only

See Note (2) Except European Community

TIMING BELT

DRIVE BELT (FOR P/STR'G PUMP, ALTERNATOR & A/CON)

VACUUM PUMP & VACUUM HOSE

VACUUM PUMP OIL HOSE

FUEL LINES, FUEL HOSE & CONNECTIONS

VACUUM HOSE (FOR EGR & THROTTLE BODY) (IF INSTALLED)

FUEL TANK AIR FILTER

F030D04JM-GAT

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

NOTE : (1) Every 500 km or before starting a long trip : "I"

(2) 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 EN 590, 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.

120

105

KILOMETERS X 1000

MONTHS

VEHICLE MAINTENANCE REQUIREMENTS

F030C03JM-GAT

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

NOTE : (1) For your convenience, it can be replaced prior to it's interval when you do maintenance of other items.

(2) INSPECT EVERY 40,000 KM AND REPLACE EVERY 100,000 KM

(3) INSPECT EVERY 40,000 KM

(4) Transfer Case Oil and Rear Axle Oil should be changed anytime they have been submerged in water.

DESCRIPTION

GENERAL MAINTENANCE

COOLING SYSTEM

COOLANT

MANUAL TRANSAXLE OIL

AUTOMATIC TRANSAXLE FLUID

BRAKE HOSES AND LINES

BRAKE 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

POWER STEERING PUMP AND HOSES

DRIVE SHAFTS AND BOOTS

AIR CONDITIONING REFRIGERANT

CLIMATE CONTROL AIR FILTER

TRANSFER CASE OIL (4WD) See Note (4)

REAR AXLE OIL (4WD) See Note (4)

PROPELLER SHAFT (4WD) (add the grease if necessary)

NO.

105

120

KILOMETERS X 1000

MONTHS

European Community Only

Except European Community

See Note (2)

See Note (3)

European Community Only

Except European Community

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 (1)

At first, replace every 48,000 km (30,000 miles) or 24 months:

after that, replace every 40,000 km (25,000 miles) or 24 months (1)

VEHICLE MAINTENANCE REQUIREMENTS

F040A02JM-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

SEVERE DRIVING CONDITIONS

A - Repeatly driving short distance of less than 8km(5miles) in normal tempera

ture 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

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

MAINTENANCE INTERVALS

ENGINE OIL AND FILTER

AIR CLEANER FILTER

SPARK PLUGS

TIMING BELT (WHEN REPLACE TIMING BELT AND INPECT WATER PUMP

(2.7 GSL)

BRAKE PADS, CALIPERS AND ROTORS

REAR BRAKE DRUMS/LININGS/PADS, PARKING BRAKE

STEERING GEAR BOX, LINKAGE & BOOTS/LOWER ARM BALL JOINT

DRIVE SHAFTS AND BOOTS

MANUAL TRANSAXLE OIL

AUTOMATIC TRANSAXLE

FLUID

CLIMATE CONTROL AIR FILTER

TRANSFER CASE OIL (4WD) *1

REAR AXLE OIL (4WD) *1

PROPELLER SHAFT (4WD)

(add the grease if necessary)

A, B, C, F, G, H, I, K

A, B, C, F, H, I, J, K

C, E

B, H

D, E, F, G

C, D, G, H

C, D, E, F

A, C, D, E, F, G, H, I, J

A, C, E, F, G, H, I

C, E

C, E, G, I

MAINTENANCE ITEM

DRIVING

CONDITION

EVERY 5,000 KM OR 6 MONTHS

EVERY 7,500 KM OR 6 MONTHS

MORE FREQUENTLY

EVERY 60,000 KM OR 48 MONTHS

MORE FREQUENTLY

EVERY 15,000 KM OR 12 MONTHS

EVERY 100,000 KM

EVERY 45,000 KM

EVERY 40,000 KM

MORE FREQUENTLY

EVERY 40,000 KM

EVERY 80,000 KM

EVERY 15,000 KM OR 12 MONTHS

European Community Only

Except European Community

MAINTENANCE

OPERATION

*1. Transfer Case Oil and Rear Axle Oil should be changed anytime they have been submerged in water.

GASOLINE For Middle East

Except Middle East

DIESEL

VEHICLE MAINTENANCE REQUIREMENTS

EXPLANATION OF SCHED-

ULED MAINTENANCE ITEMS

F060M01A-AAT

o Engine Oil and Filter

The engine oil and filter should be

changed at the intervals specified in

the maintenance schedule. If the car

is being driven in severe conditions,

more frequent oil and filter changes

are required.

F060B01A-AAT

o Drive Belts

Inspect all drive belts for evidence of

cuts, cracks, excessive wear or oil

saturation and replace if necessary.

Drive belts should be checked periodi-

cally for proper tension and adjusted

as necessary.

F060C01A-AAT

o Fuel Filter

A clogged filter can limit the speed at

which the vehicle may be driven, dam-

age the emission system and cause

hard starting. If an excessive amount

of foreign matter accumulates in the

fuel tank, the filter may require re-

placement more frequently.

After installing a new filter, run the

engine for several minutes, and check

for leaks at the connections. Fuel fil-

ters should be installed by trained

technicians.

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 and

high pressure pipes are subject to

high pressure even after the engine

stopped. The fuel jet produced by

fuel leaks may cause serious injury,

if it touch the body. People using

pacemakers should not move than

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.

F060D01TB-AAT

o Fuel Lines, Fuel Hoses and

Connections

Check the fuel lines, fuel hoses and

connections for leakage and damage.

Have a trained technician replace any

damaged or leaking parts immediately.

VEHICLE MAINTENANCE REQUIREMENTS

F060H01A-AAT

o Air Cleaner Filter

A Genuine Hyundai air cleaner filter is

recommended when the filter is re-

placed.

F060J01A-AAT

o Spark Plugs

(For Gasoline Engine)

Make sure to install new spark plugs

of the correct heat range.

F060E01A-AAT

o Timing Belt

Inspect all parts related to the timing

belt for damage and deformation. Re-

place any damaged parts immediately.

F060G01A-AAT

o Vapor Hose and Fuel Filler Cap

The vapor hose and fuel filler cap

should be inspected at those intervals

specified in the maintenance sched-

ule. Make sure that a new vapor hose

or fuel filler cap is correctly replaced.

F060F01A-AAT

o Vacuum, 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 excessive

swelling indicate deterioration. Particu-

lar attention should be paid to examine

those hose surfaces nearest to high

heat sources, such as the exhaust

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 heat

damage or mechanical wear. Inspect

all hose connections, such as clamps

and couplings, to make sure they are

secure, and that no leaks are present.

Hoses should be replaced immedi-

ately if there is any evidence of dete-

rioration or damage.

F070C01A-AAT

o Coolant

The coolant should be changed at

the intervals specified in the mainte-

nance schedule.

F070B01A-GAT

o Cooling System

Check the cooling system part, such

as radiator, coolant reservoir, hoses

and connections for leakage and dam-

age. Replace any damaged parts.

VEHICLE MAINTENANCE REQUIREMENTS

F070L01A-AAT

o Suspension Mounting Bolts

Check the suspension connections for

looseness or damage. Retighten to the

specified torque.

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 exhaust

gas leakage. Tighten connections or

replace parts as necessary.

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 be

between 'MIN' and 'MAX' marks on the

side of the reservoir. Use only hydrau-

lic brake fluid conforming to DOT 3 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.

F070E05A-AAT

o Automatic Transaxle Fluid

The fluid level should be in the "HOT"

range of the dipstick, after the engine

and transaxle are at normal operating

temperature. Check the automatic

transaxle fluid level with the engine

running and the transaxle in neutral,

with the parking brake properly ap-

plied. Use Hyundai Genuine ATF SP-

III, DIAMOND ATF SP-III, SK ATF

SP-III or other brands appraoved by

Hyundai Motor Co., when adding or

changing fluid.

F070D01A-AAT

o Manual Transaxle Oil

Inspect the manual transaxle oil ac-

cording to the maintenance schedule.

NOTE:

If the oil level is low, check for

possible leaks before adding oil. Do

not overfill.

VEHICLE MAINTENANCE REQUIREMENTS

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 dam-

age. Check the dust boots and ball

joints for deterioration, cracks, or dam-

age. Replace any damaged 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.

F070P01A-AAT

o Drive Shafts and Boots

Check the drive shafts, boots and

clamps for cracks, deterioration, or

damage. Replace any damaged parts

and, if necessary, repack the grease.

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.

VEHICLE MAINTENANCE REQUIREMENTS for Your Hyundai Tucson SUV First Generation (2004-2009)

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