Content .. 9 10 11 12 ..

Hyundai H-100 Truck (2012 year). Instruction - part 11

DO-IT-YOURSELF MAINTENANCE

CHECKING THE BATTERY

4. Insert the power connector in the

G210A01A-AAT

The fluid in the battery contains a strong

opposite direction.

solution of sulfuric acid, which is poi-

sonous and highly corrosive. Be careful

NOTE:

not to spill it on yourself or the car. If you

o If the power connector is pulled

do spill battery fluid on yourself, imme-

up from the fuse panel, the warn-

diately do the following:

ing chime, audio, clock and inte-

If battery fluid is on your skin, flush

rior lamps, etc., will not operate.

the affected areas with water for at

The following items must be reset

least 15 minutes and then seek medi-

after replacement.

cal assistance.

- Digital Clock

If battery fluid is in your eyes, rinse

o Even though the power connector

out your eyes with water and get

D010B01HR

is pulled up, the battery can still

medical assistance as soon as pos-

be discharged by operation of the

sible. While you are being driven to

headlights or other electrical de-

get medical assistance, continue to

WARNING:

vices.

rinse your eyes by using a sponge

Batteries can be dangerous! When

or soft cloth saturated with water.

working with batteries, carefully ob-

If you swallow battery fluid, drink a

serve the following precautions to

large quantity of water or milk fol-

avoid serious injuries.

lowed by milk of magnesia, eat a raw

egg or drink vegetable oil. Get medi-

cal assistance as soon as possible.

CAUTION:

If you connect unauthorized elec-

tronic devices to the battery, the bat-

tery may be discharged. Never use

unauthorized devices.

6 DO-IT-YOURSELF MAINTENANCE

While batteries are being charged (ei-

G210B01HR-GET

If any electrolyte gets into

ther by a battery charger or by the

Checking the Battery

your eyes, flush your eyes

vehicle's alternator), they produce ex-

Keep the battery clean. Any evidence

with clean water for at least

plosive gases. Always observe these

of corrosion around the battery posts or

15 minutes and get immedi-

warnings to prevent injuries from oc-

terminals should be removed using a

ate medical attention. If pos-

curring:

solution of household baking soda and

sible, continue to apply

warm water. After the battery terminals

water with a sponge or cloth

Charge batteries only in a well venti-

are dry, cover them with a light coating

until medical attention is re-

lated area.

of grease.

ceived.

Do not permit flames, sparks or

If electrolyte gets on your

smoking in the area.

skin, thoroughly wash the

Keep children away from the area.

WARNING:

contacted area.

Always read the following

If you feel a pain or a burn-

instructions carefully when

ing sensation, get medical

handling a battery.

attention immediately.

Keep lighted cigarettes and

Wear eye protection when

all other flames or sparks

charging or working near a

away from the battery.

battery.

Hydrogen, which is a highly

Always provide ventilation

combustible gas, is always

when working in an en-

present in battery cells and

closed space.

may explode if ignited.

An inappropriately disposed

Keep batteries out of the

battery can be harmful to

reach of children because

the environment and human

batteries contain highly cor-

health. Dispose the battery

rosive SULFURIC ACID. Do

according to your local

not allow battery acid to con-

law(s) or regulation.

tact your skin, eyes, cloth-

ing or paint finish.

DO-IT-YOURSELF MAINTENANCE

CHECKING ELECTRIC

POWER STEERING FLUID

COOLING FANS

LEVEL

G220A01A-AAT

G230A03A-GAT

o When lifting a plastic-cased bat-

tery, excessive pressure on the

case may cause battery acid to

WARNING:

leak, resulting in personal injury.

The cooling fan is controlled by en-

Lift with a battery carrier or with

gine coolant temperature and may

your hands on opposite corners.

sometimes operate even when the

o Never attempt to charge the bat-

engine is not running. Use extreme

tery when the battery cables are

caution when working near the

connected.

blades of the cooling fan, so that you

o The electrical ignition system

are not injured by a rotating fan

works with high voltage.

blade. As the engine coolant temper-

Never touch these components

HHR5014

ature decreases the fan will automat-

with the engine running or the

ically shut off. This is a normal con-

The power steering fluid level should be

ignition switched on.

dition.

checked regularly.

To check the power steering fluid level,

G220B01A-AAT

be sure the ignition is "OFF", then

Checking Engine Cooling Fan

check to make certain that the power

steering fluid level is between the "MAX"

The engine cooling fan should come on

and "MIN" level markings on the fluid

automatically if the engine coolant tem-

reservoir.

perature is high.

NOTE:

G220C01TB-GAT

Grinding noise from the power steer-

Checking Condenser Cooling

ing pump may be heard immediately

Fan

after the engine is started in extremely

cold conditions (below - 20°C). If the

When the air conditioning is in opera-

noise stops during warm up, there is

tion, the condenser cooling fan comes

no abnormal function in the system.

on automatically to be controlled by

ECU.

6 DO-IT-YOURSELF MAINTENANCE

FUEL FILTER

It is due to a power steering fluid

G350B01HR-GAT

characteristic in extremely cold con-

BLEEDING THE FUEL SYSTEM

ditions.

Recommended Fluid

Use PSF-3 type fluid

NOTE:

Do not start the engine when the

power steering oil reservoir is

empty.

HHR4047

2. Pump the hand pump until there are

G240A01A-AAT

HHR4046

no more bubbles in the fuel coming

POWER STEERING HOSES

The fuel system should be bled to

out of the air plug. When doing this,

It is suggested that you check the

remove air as described in the illustra-

place a cloth around the air plug to

power steering hose connections for

tion if the fuel supply is exhausted

prevent the escaping fuel from spew-

fluid leakage at regular intervals. The

during travel, when the fuel filter is

ing about.

power steering hoses should be re-

replaced, or if the vehicle is not used for

3. Tighten the air plug when there are no

placed if there is severe surface crack-

a long time.

more bubbles in the fuel.

ing, scuffing or worn spots. Deteriora-

4. Continue pumping until the hand

1. Loosen the air plug at the upper part

tion of the hose could cause prema-

pump becomes stiff.

of the fuel filter.

ture failure.

5. Finally, check to be sure that there is

no leakage of fuel.

NOTE:

If in doubt, consult your nearest au-

The fuel filter is located under the

thorized HYUNDAI dealer.

driver's seat. To bleed the fuel sys-

tem, first tilt the driver's seatback

forward. (Refer to "To Inspect the

Engine Compartment Under the

Driver's Seat." on page 1-12.)

DO-IT-YOURSELF MAINTENANCE

G300A01HR-GAT

REMOVAL OF WATER FROM

WARNING:

THE FUEL FILTER

o Do not smoke or have any other

open flame near the vehicle while

bleeding the fuel system.

o Be sure to carefully clean away

any fuel which spilled onto nearby

parts coming out of the air plug,

because such accumulations of

fuel might ignite and cause a fire.

HHR4047

2. Operate the hand pump slowly 6 or 7

times in order to force the water out

HHR4045

through the drain plug.

If the fuel filter warning light illuminates

3. Tighten the drain plug when water no

during driving, it indicates that water

longer comes out.

has accumulated in the fuel filter. If this

4. Loosen the air plug and bleed the air.

occurs, remove the water as described

(Refer to "Bleeding the fuel system")

below.

5. Check to be sure that the warning

light illuminates when the ignition

1. Loosen the drain plug at the bottom

key is turned to "ON", and that it

of the fuel filter.

goes off when the engine is started.

If in doubt, consult your nearest au-

thorized HYUNDAI dealer.

6 DO-IT-YOURSELF MAINTENANCE

HEADLIGHT AIMING

ADJUSTMENT

G290A01FC-GAT

NOTE:

It is recommended that water accu-

Before performing aiming adjustment,

mulated in the fuel filter should be

make sure of the following.

removed by an authorized Hyundai

Vertical aiming

dealer.

1. Keep all tires inflated to the correct

pressure.

2. Place the vehicle on level ground

and press the front bumper and rear

WARNING:

bumper down several times. Place

o Do not smoke or have any other

the vehicle at a distance of 3,000

Horizontal

open flame near the vehicle while

mm (118 in.) from the test wall.

aiming

G290A01HR

bleeding the fuel system.

3. See that the vehicle is unloaded

o Be sure to carefully wipe away any

(except for full levels of coolant,

7. Adjust each cut-off line of the low

water drained out in this manner,

engine oil and fuel, and spare tire,

beam to the parallel line with a phillips

because the fuel mixed in the wa-

jack, and tools).

screwdriver - VERTICAL AIMING.

ter might be ignited and result in a

4. Clean the head lights lens and turn

8. Adjust each cut-off line of the low

fire.

on the headlight (low beam).

beam to each vertical line with a

5. Open the hood.

phillips screwdriver - HORIZONTAL

6. Draw the vertical line (through the

AIMING.

center of each headlight beam pat-

tern) and the horizontal line (through

the center of each headlight beam

pattern) on the aiming screen.

And then, draw a horizontal parallel

line at 30 mm (1.18 in.) under the

horizontal line.

DO-IT-YOURSELF MAINTENANCE

REPLACEMENT OF LIGHT

BULBS

G290B01HR-GAT

If the vehicle has had front body repair

G260A03A-AAT

Adjustment After Headlight As-

and the headlight assembly has been

Before attempting to replace a light

sembly Replacement

replaced, an headlight aiming should be

bulb, be sure the switch is turned to the

checked using an aiming screen as

"OFF" position.

30mm (1.18 in.) Vertical line

shown in the illustration. Turn on the

The next paragraph shows how to reach

Horizontal line

headlight switch. (Low Beam Position)

the light bulbs so they may be changed.

"P"

Be sure to replace the burned-out bulb

1. Adjust headlights so that main axis

with one of the same number and watt-

of light is parallel to center line of the

age rating.

body and is aligned with point "P"

See page 6-37 for the wattage descrip-

Cut-off line

shown in the illustration.

tions.

Ground

2. Dotted lines in the illustration show

line

the center of headlights.

G290B01HR-1

CAUTION:

SPECIFICATIONS:

o Keep the lamps out of contact with

Front view

"H"

petroleum products, such as oil,

Horizontal center line of headlights

Horizontal line

30mm (1.18 in.)

gasoline, etc.

from ground.

o After heavy, driving rain or wash-

Low Deck: 815 mm (32.1 in.)

Vertical line

ing, headlight and taillight lenses

"P"

High Deck: 820 mm (32.3 in.)

could appear frosty. This condi-

tion is caused by the temperature

"W"

difference between the lamp in-

Distance between each headlight

Cut-off line

side and outside. This is similar to

center : 1,330 mm (52.4 in.)

the condensation on your win-

dows inside your vehicle during

"L"

Ground line

G290B02HR-1

the rain and doesn’t indicate a

Distance between the headlights

problem with your vehicle. If the

and the wall that the lights are tested

water leaks into the lamp bulb

against.

circuitry, have the vehicle checked

: 3,000 mm (118 in.).

by an Authorized Hyundai Dealer.

6 DO-IT-YOURSELF MAINTENANCE

G270A01HR-GAT

Headlight Bulb

1. Allow the bulb to cool. Wear eye

protection.

2. Always grasp the bulb by its terminal

plate base, avoid touching the glass.

G270A01HR

HHR5031

4. Open the hood and remove a head-

6. Remove the dust cover.

light assembly mounting bolt with a

spanner.

G270A02HR

3. Open the door and remove a head-

light assembly mounting screw with

a philips screwdriver.

HHR5032

HHR5030

7. Push the bulb spring to remove the

headlight bulb.

5. Disconnect the power cord from the

bulb base in the back of the head-

light.

DO-IT-YOURSELF MAINTENANCE

G270B01HR-GAT

Front Turn Signal light /

Position Light

HHR5033

G270A03O

8. Remove the protective cap from the

replacement bulb and install the new

G270A02HR

bulb by matching the plastic base

WARNING:

with the headlight hole. Reattach the

1. Open the door and remove a head-

The halogen bulb contains gas un-

bulb spring and install the dust cover.

light assembly mounting screw with

der pressure and if impacted could

Reconnect the power cord.

a philips screwdriver.

shatter, resulting in flying fragments.

9. Use the protective cap and carton to

Always wear eye protection when

dispose of the old bulb.

servicing the bulb. Protect the bulb

10.Check for proper headlight aim.

against abrasions or scratches and

against liquids when lighted. Turn

the bulb on only when installed in a

headlight. Replace the headlight if

damaged or cracked. Keep the bulb

out of the reach of children and dis-

pose of the used bulb with care.

G270A01HR

6 DO-IT-YOURSELF MAINTENANCE

2. Open the hood and remove a head-

G270D01HR-GAT

light assembly mounting bolt with a

Rear Combination Light

spanner.

(1)

(2)

HHR5035

4. To replace the front turn signal light

G270D01HR

(1) or position light (2), take it out

from the bulb holder by turning it

1. Disconnect the power cord from the

HHR5034

counterclockwise.

bulb.

3. Disconnect the power cord from the

5. Install the new bulb.

bulb.

G270D02HR

2. Remove the cover by pressing the

both sides of the cover.

DO-IT-YOURSELF MAINTENANCE

G270I01HR-GAT

2. Take the bulb out from the bulb

(2)

License Plate Light

holder by turning it counterclockwise

and disconnect the power code.

3. Install the new bulb.

G270E01A-GAT

(3)

Side Repeater (If Installed)

(1)

HHR5038

3. To replace the rear combination light

OHR058100

(stop/tail light, turn signal light or

back-up light), take it out from the

1. Remove the mounting screws of the

bulb holder by turning it counter-

license plate light with a phillips

clockwise.

screwdriver.

(1) Turn Signal Light

G270E01HR

(2) Stop/Tail Light

(3) Back-up Light

1. Push the cover toward the front of

vehicle and remove it.

4. Install the new bulb.

OHR058101

6 DO-IT-YOURSELF MAINTENANCE

G270F02HR-GAT

Rear Fog Light (If Installed)

G270E02HR

G270F03HR

2. Disconnect the power code.

2. Take the bulb out from the bulb

G270F02HR

holder by turning it counterclock-

1. Remove the cover by pressing the

wise.

both sides of the cover.

3. Replace with a new bulb. (21 W)

G270E03HR

3. Replace with a new bulb.

DO-IT-YOURSELF MAINTENANCE

G270G01HR-GAT

G270H01HR-GAT

Map Light

Interior Light

(If installed, With Spectacle Case)

(If installed,Without Spectacle Case)

HHR5039

G270H01HR

1. Remove the cover with a flat-head

screwdriver.

G270G02HR

G270H02HR

2. Replace with a new bulb.

6 DO-IT-YOURSELF MAINTENANCE

BULB WATTAGES

G280A03HR-GAT

OHR058102

No.

Part Name

Wattage

Socket Type

No.

Part Name

Wattage

Socket Type

Front Fog Light (If Installed)

PG13

Interior Light

S8.5/8.5

Front Position Light

W2.1 x 9.5D

(If installed, Without Spectacle Case)

Headlight (High/Low)

60/55

P43t-38

Rear Combination

Turn Signal Light

BA 15s

Front Turn Signal Light

BA 15s

Light

Stop/Tail Light

21/5

BAY 15d

Side Repeater (If Installed)

W2.1 x 9.5D

Back-up Light

W2.1 x 9.5D

Map Light

License Plate Light

W2.1 x 9.5D

(If installed, With Spectacle Case)

DO-IT-YOURSELF MAINTENANCE

FUSE PANEL DESCRIPTION

G200C01HR-GAT

DESCRIPTION

AMPERAGES

CIRCUIT PROTECTED

Engine Compartment

BATT

100A

Generator

GLOW

80A

Glow relay

IGN

50A

Start relay, lgnition switch

ECU

20A

Engine control relay

BATT

50A

I/P Fuse box (A/Con, Hazard, DR Lock), Power connector

LAMP

40A

P/WDW fusible link, Front Fog fuse, Tail lamp relay

FUSIBLE

COND

30A

Condenser fan relay

LINK

ABS2

30A

Not used

PTC1

40A

Not used

ABS1

30A

Not used

PTC2

40A

Not used

BLWR

30A

Blower relay

PTC3

40A

Not used

FFHS

30A

Not used

GLOW

10A

ECM

ALT_S

10A

Generator

STOP

10A

Stop lamp switch

HORN

10A

Horn relay

FUSE

A/CON

10A

A/Con relay

TCU

10A

Not used

ECU1

15A

Not used

G200C02HR

ECU2

10A

Not used

NOTE:

Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time of printing.

When you inspect the fuse box on your vehicle, refer to the fuse box label.

6 DO-IT-YOURSELF MAINTENANCE

G200E01HR-GAT

Inner Panel

G200E02HR

DO-IT-YOURSELF MAINTENANCE

DESCRIPTION

AMPERAGES

CIRCUIT PROTECTED

FUSIBLE

P/WINDOW

30A

Power window relay

LINK

START

10A

Start relay, Glow control module, ECM

FRT FOG

10A

Front fog lamp relay

H/LP LH

10A

Left head lamp, Instrument cluster

H/LP RH

10A

Right head lamp

IGN 2

10A

Heater control switch, ETACM, Head lamp leveling switch, Blower relay

WIPER

20A

Wiper motor, Multi-function switch

RR FOG

10A

Rear fog lamp relay

C/LIGHT

15A

Cigarette lighter

P/OUT

15A

Not used

AUDIO

10A

Audio

RR P/WDW

25A

Power window switch

PTO

10A

Not used

TAIL RH

10A

Right position lamp, Right rear combination lamp, License plate lamp

FUSE

THIL LH

10A

Left position lamp, Left rear combination lamp

ABS

10A

Not used

CLUSTER

10A

Instrument cluster, Generator resister

ECU

10A

ECM

T/SIG

10A

Hazard switch, Back-up lamp switch

IGN 1

10A

ETACM

EGR solenoid valve #1, #2 (2.5 TCI), Glow control module (2.6 N/A),

IGN COIL

10A

Fuel water sensor, Neutral switch

O/S MIRR

10A

Not used

FOLD'G

PTC HTR

10A

Heater control switch

HTD GLASS

15A

Rear window defroster switch

HAZARD

15A

Hazard switch

DR LOCK

15A

ETACM, Left front door lock actuator

ROOM LP

15A

Room lamp, Door warning switch, Audio, ETACM

Content .. 9 10 11 12 ..