Workshop Manual for Refine MPV Maintenance

Maintenance

I. Recommended lubricants

1. Specification

Component Specification Remarks

Engine oil API over Class SG Refer to SAE viscosity

sequence number for detail

Manual gearbox API Class GL-4 SAE Class No.:

SAE 75W/90

Automatic gearbox Hyundai original driving axle oil,

Original DIAMOND ATF SP-II M

Brake DOT 3 or DOT 4

Concentration standard 50%

(ordinary)
Cooling system High quality ethylene base glycol
Concentration standard 40%
(tropical)

Power steering PSF-3

Drive axle rod, parking brake cable Multi-functional grease NLGI

mechanical device, engine hood lock grade #2
and hook, door locks, seat adjusting
devices, luggage boot lock, door
hinges and luggage boot hinges

2. Filling amount

Note Capacity (L)

2.5 (L4) 2.4 (L4)
Engine oil Oil sump 5.8 3.7
Engine oil filter 0.7 0.3
Total 6.5 4.0
Cooling system 8.7 7
Manual gearbox 2.5 2.5
Automatic gearbox 8.2 8.5
Power steering 1.0 1.0

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 Workshop Manual for Refine MPV Maintenance

II. Replacement of air filter

The air filter will become dirt during use, resulting

in substantial reduction in filtering effect. Replace
it with a new filter when necessary.

1. Loosen the clamp fixing the air filter cap by

removing the two fixing bolts at the air inlet
pipe mouth.
2. Remove the air filter cap and take out the air
filter element

Caution: Take care when removing the air filter

cap, as the air inlet pipe contains the air flow
sensor.

3. If there is dust on the element, blow it clean

with compressed air from inside. If it is dirt,
replace with a new air filter.
4. Check the air filter housing for presence of
dust, and blow it clean with compressed air.

III. Replacement of engine oil

1. Check the engine oil
1) Park the vehicle on a level ground.
2) Turn off the engine.

Note:
If the vehicle is not used for a long time, turn
the engine for several minutes, and turn off the
engine and wait for at least 5 minutes before
checking the engine oil level.

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 Workshop Manual for Refine MPV Maintenance
3) Pull out the engine oil dipstick and check the oil
level is within the range shown on the dipstick.
If the oil level is found below the lower limit
(“L”mark), fill oil up to the “F”mark.
Note:
OK
For oil filling, use the engine oil in correct
grade.

4) Check if the engine oil is contaminated, or

mixed with cooling liquid or gasoline and also
check if it is in appropriate viscosity.

2. Selection of engine oil

Recommended API class: SD or above, SE or above
Recommended SAE viscosity class:

Expected temperature
range before next oil Recommended SAE viscosity No.
change

1. It is subject to restriction by running conditions and environment.

2. This value is not recommended for vehicles running at high speed continuously.

Note:
To protect the engine and bring into full play the engine performance, you must select lubricating oil meeting the
following requirements:
1) It can well meet the requirements of API classification.
2) It has suitable SAE grade No. for expected atmospheric temperature range.
Lubricant without SAE grade No. and API service classification on its container should not be used.

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 Workshop Manual for Refine MPV Maintenance
3. Replacing engine oil
1) Run the engine until the normal operation
temperature is reached, and check for oil leakage.
2) Turn off the engine
3) Remove the engine oil cap and drain plug and
drain out the engine oil.
4) Tighten the drain plug to the specified torque.
Tightening torque for the oil sump drain plug:
35-45 Nm
Note:
Replace with a new drain plug washer
whenever the drain plug is tightened.

5) Fill in new engine oil via the open engine oil

cap.

Oil drain and filling: 4.3L

Note:
Do not fill excessive oil. This will cause bubbling
in engine oil and loss of oil pressure.

6) Mount the oil cap.

7) Start and run the engine for several minutes, and
check for any oil leakage.
8) Turn off the engine and check the oil level. Fill
more oil when necessary.

IV. Replacing engine oil filter

All engines from Hyundai Motor Company are
Part No.
equipped with high quality engine oil filters that
can be used freely. This type of engine oil filter has
been recommended as substituting engine oil filter
for all vehicles. The engine oil filters replaced in
after-sale service often have substantial difference
in quality.
High quality substituting engine oil filters should
be used to ensure most effective service. Before
installing an engine oil filter, make sure that all
rubber gaskets of the old engine oil filter have been
removed from the contact surface of the engine
body.

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 Workshop Manual for Refine MPV Maintenance
Procedure for replacing engine oil filter
1. Use the spanner for engine oil filter to
remove the engine oil filter.
2. Before mounting a new engine oil filter on
the engine, apply clean engine oil onto the
rubber gaskets.
Apply oil
3. Tighten the engine oil filter to the specified
torque.
Engine oil filter: 12-16Nm
4. Start and run the engine, and check for any
oil leakage.
5. Turn off the engine and check the oil level.
Fill more oil when necessary.

V. Check leakage of cooling liquid

1. Loosen the cooling liquid filling port cap.
2. Confirm that the cooling liquid level is at the
neck of filling port.
3. Fit a radiator cap tester at the cooling liquid
filling port and apply a pressure of 150KPa. Radiator cap
Maintain this status for 2min and check for tester
any leakage on the radiator, hose or
connector.
Note:
1. Do not open conversation cooling liquid
filling port cap directly as the temperature of
cooling liquid in the radiator may be very
high. Maintain this system after the vehicle
has cooled down to prevent cooling liquid at
high temperature from sprouting out to cause
personal injury.
2. Take care not to spill out the cooling liquid
when removing the tester.
3. Make sure that unnecessary objects in the area
have all been removed.
4. Take care when mounting and removing the
tester and making test, to avoid deform the
radiator filling port neck.
5. In case of any leakage, repair it or replace
with suitable parts.

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 Workshop Manual for Refine MPV Maintenance
Radiator cap pressure test
1. Mount the cap on the tester with a connector.
Connector
2. Increase the pressure until the meter stops
moving
Main valve opening pressure: 107.9KPa±14.7KPa
Main valve closing pressure: 83.4KPa

3. Check that the pressure is kept at or above the

limit value.
4. Replace the radiator cap if the reading is not
kept at or above the limit value

Note
Make sure that the cap is clean before the test,
as any rust or other foreign matter on the cap
sealing will result in inaccurate reading.

densimeter
Specific gravity test
1. Measure the specific gravity of the cooling
liquid using a specific gravity meter.
2. Measure the cooling liquid temperature, and
calculate the concentration with reference to
the table below using the relations between
specific gravity and temperature.

Relationship between cooling liquid concentration

and specific gravity
Cooling liquid temperature ℃ and specific gravity
Freezing Safe operation cooling liquid
temperature temperature concentration
10 20 30 40 50
℃ ℃ (specific volume)

1.054 1.050 1.046 1.042 1.036 -16 -11 30%

1.063 1.058 1.054 1.049 1.044 -20 -15 35%
1.071 1.067 1.062 1.057 1.052 -25 -20 40%
1.079 1.074 1.069 1.064 1.058 -30 -25 45%
1.087 1.082 1.076 1.070 1.064 -36 -31 50%
1.095 1.090 1.084 1.077 1.070 -42 -37 55%
1.103 1.098 1.092 1.084 1.076 -50 -45 60%
Example:
When the measured specific gravity is 1.058 at a cooling liquid temperature of 20℃, the safe operation
temperature is -15℃.

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 Workshop Manual for Refine MPV Maintenance
Caution:
◆ If the concentration of cooling liquid is below
30%, its anti-corrosion characteristics will be Pump pulley
adversely affected. Power steering
pulley Air conditioner
◆ If the concentration is over 60%, the pulley
anti-freezing and engine cooling performance will Air
conditioner
be weakened, resulting in adverse effect on the compressor
pulley
engine. Therefore, the concentration value should
be kept within the specified range. V-belt for
generator
◆ Do not mix anti-freezing liquid of different
types.
Recommended anti-freezing liquid: ethylene
glycol base (aluminum water tanks)
Mixing ration of anti-freezing liquid in cooling Generator Air
pulley conditioner
liquid: Crankshaft
pulley compressor
50% [except in tropical areas] pulley
40% [in tropical areas]

V. Adjusting driving belt tension

1. Check if the belt is damaged, and place it in the
pulley groove in a correct manner.
2. Apply a force of 100N as shown at the back of
the belt between gears in the middle, and measure
the deflection value with a tensiometer.
Note:
1. When fitting a V-stripped belt, check if the
V-strips are correctly aligned.
2. If any noise or sliding has been detected,
check the belt for any damage or breaking on
the pulley surface and the gears for any
scratching and also check the deflection of the
belt.

Standard values
Adjustment
Item Check
New Old
Deflection mm 9.0-10.4 7.5-9.0 10
Generator driving belt
Tension N 350-500 600-700 6.0-7.0
Deflection mm 8 5.0-5.5 6.0-7.0
Compressor driving belt
Tension N 250-500 470-570 320-400
Power steering driving belt Deflection mm 6.0-9.0

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 Workshop Manual for Refine MPV Maintenance
Note:
1. Belt tension must be measured in the middle
of a belt between specified gears.
2. When fitting a new belt, adjust the tension to
the median value of the standard range
indicated in the “New” column of the table
above. Idle the engine for 5 min or longer
time, check the standard value in the “Check”
column.
3. When adjusting a used old belt or a newly
fitted belt having run for over 5 min, refer to
the standard value indicated in “Old”column
of the table.
4. For periodical check, refer to the standard
value in the “Check”column.

Displayed value
Type A tensiometer Scale
During measurement, do not let the reading portion
Measuring rod
of the tensiometer contact with any other object. Hook
Measuring
rod
V-stripped belt
Hook

Type B tensiometer RESET pushbutton

1. During measurement, turn the reset knob in the
arrow direction and set the pointer to the RESET RESET position
position.
2. The pointer will still indicate the tension when
the tensiometer is removed from the belt. Read the Measuring rod
tension value after removing the tensiometer. Hook

V-stripped belt

Adjusting generator belt

Note:
Adjustor locking nut B
If the belt is excessively loose, it will produce Tension adjustor nut
noise and speed up the wearing. Pump pulley
Increase tension
A belt too tight will damage the engine cooling
Generator nut A Crankshaft
liquid pump bearing or generator.
pulley
1. Loosen the generator nut “A” and tension
adjustor locking bolt “B”.

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 Workshop Manual for Refine MPV Maintenance
2. Adjust the belt tension to the specified value
using the tension adjustor bolt.
3. Tighten the adjustor locking bolt “B”.
4. Tighten the generator nut “A”.
5. Check the belt tension or deflection, and
make adjustment again when necessary.

Tightening torque
Generator nut A: 35-55 Nm
Adjustor locking nut B: 20-25 Nm
Tension adjustor bolt: 8-12 Nm

Adjust Power steering and compressor belts

1. Loosen the tension pulley adjusting bolt A.

2. Adjust the belt deflection using adjustor bolt B.
3. Tighten bolt A.
4. Check the belt deflection again, and make
adjustment again if necessary.

Note:
Turn the engine with the handle at least one
turn before the second check.

VII. Manual gearbox (check the oil

level)

Check each part for oil leakage, and check oil level
after removing the filling plug. Contaminated oil
should be replaced with new oil.
1. Park the vehicle at a level ground and remove
the filling plug to confirm that the oil level is
flush with the plug hole.
2. Check if the gearbox oil is contaminated.
Gearbox oil (replacement)
1. Park the vehicle at a level position and remove
the magnetic plug to drain out the gearbox oil.
2. Replace with a new washer and fit the plug
again.
3. Fill gearbox oil via the filling port plug until
the level is flush with the plug hole.

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 Workshop Manual for Refine MPV Maintenance

VIII. Maintenance of steering system

Check the steering rod system
1. Check the free travel of the steering wheel.
Maximum free travel of steering wheel: 30 mm
2. Check the steering rod system for any looseness or
damage.
a. There must be no excessive large gap at the end of
transversal rod end.
b. The dust sealing ring and protection hood must not
be damaged
c. The protection hood clamp must not be loosened.
Steering and driving shaft protection hoods
1. Special care must be taken for aluminum wheels. Any
salt or chemical attached to wheels should be flushed
whenever possible. After cleaning the wheels, apply a
thin wax layer to prevent corrosion.
2. When cleaning the vehicle with steam, do not apply
steam directly to aluminum wheels.
o Clean the hub surface
o After tightening the wheel nuts with hand, tighten
them according to the instruction manual.
o Do not tighten the wheel nuts with tightening
spanner or by treading on the spanner.
Do not apply lubricant on threaded parts.

Power steering liquid level (check oil level)

1. Park the vehicle at a level position, start the engine and
then turn the steering wheel several time, and wait for
the oil temperature to rise to about 50℃.
2. Idle the engine and turn the steering wheel to the left
and right several times in complete turns, to check if
there is any foam in the oil in the reservoir and also
check the oil level. If necessary, make up oil via the
filling port into the reservoir.

Power steering hose (check for deterioration or

leakage)
1. Check the hose connectors for any leakage.
2. Any power steering hose with serious surface crack,
elongation, scratching or wearing should be replaced.
Deterioration of hose will result in premature failure of
the system.

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 Workshop Manual for Refine MPV Maintenance
Spherical joint and steering rod system seals, steering
and driving shaft protection hoods
1. These parts require no lubrication as they have been
permanently lubricated in the factory. Damaged seal
rings and protection hoods should be replaced in a
timely manner to prevent leakage or contamination of
grease.
2. Check the dust end cover and protection hoods for
correct sealing, leakage or damage. Any one with
defect should be replaced.

XI. Check the brake piping

1. Check all the brake piping and hoses for damage,
wearing, crack, corrosion, leakage, bending and
torsion.
2. Check that all clamps are properly tightened.
3. Check the piping for through passage at sharp angle
transition, moving parts and drain systems.

Front wheel disc brake liner

Check for wearing and contamination of oil. Always
Turn the disc
replace the brake liners in complete set.
Note:
If squealing or rubbing noise is detected with brake
during running, check if the liner wearing indicator is
in contact with the disc. If yes, replace the brake liner.
Brake liners of both left and right wheels should be
replaced at the same time. Do not separate or mix a pair
of brake liners. All liners must be replaced in complete
sets. Liner friction sheet thickness [limit value]: 2.0 mm.

Rear wheel drum brake friction liner and rear wheel

brake cylinder:
1. Remove the brake drum and check the brake shoe
friction lining for wearing. Check with hand the brake
gap automatic adjusting device for flexible operation
and the gears for correct engaging. To ensure flexible
operation, apply a thin layer of grease on the friction
surfaces between the adjusting device and rod shaft.
2. Check the wheel brake cylinder protection hood for
leakage. Visually check the protection hood for cutting,
breaking or thermal crack (small amount of oil on the
protection hood is not leakage but the anti-corrosion
liquid for the assembly.).

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 Workshop Manual for Refine MPV Maintenance

Check the brake shoe for wearing

Friction lining thickness [limit value]: 0.8 mm
Check braking liquid level
1. Check the braking liquid level in the main cylinder
reservoir.
2. The level should be between “MIN” and “MAX”
scales.
3. If the level is below the scale “MIN”, fill new braking
liquid until it reached the “MAX”.
Replacing braking liquid
1. Refer to the venting procedure for BR (brake system).
2. For vehicles equipped with ABS system, refer to the
section (Brake System).
3. Connect a plastic hose on the vent plug of wheel brake
cylinder, and connect the other end of the hose to a
container to receive braking liquid.
4. Tread on the braking pedal several times. Then loosen
the venting plug (keeping the braking pedal pressed),
and tighten the plug when no more braking liquid
flows out.
5. Repeat the above operation until there is no bubble in
the braking liquid.
6. Repeat these steps for other brake cylinders.
7. Fill new braking liquid into the reservoir tank until the
level reaches the scale “MAX”.
Braking liquid : DOT 3 or DOT4

X. Tyre chains and snow tyres

Tyre chains can be used only on front wheels. Do not use
tyre chains on rear wheels. When it is necessary to use
snow tyres, use then on all 4 wheels for additional
maneuverability and safety.

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