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2002 Hyundai Terracan Factory Service/Repair/ Workshop Manual

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🏷️ Basic Information Identification Make: Hyundai Model: Terracan Year: 2002 Codes Vin Prefix Common: KNACP 👋 Introduction Market Position Segment: Mid-size SUV Segment Description: The Hyundai Terracan was positioned as a body-on-frame, rugged SUV, competing with vehicles like the Toyota 4Runner, Mitsubishi Montero Sport, and Nissan Pathfinder. Competitive Analysis Key Competitors 2002: Toyota 4Runner, Mitsubishi Montero Sport, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee Key Features Body Construction: Body-on-frame chassis for durability and off-road capability Drivetrain Options: Available in 2WD and 4WD (often with electronic transfer case and low-range gearing) Target Audience: Consumers seeking a capable, practical SUV for family use, towing, and light to moderate off-roading. 📋 Manual Details Coverage Areas Primary Coverage: Maintenance and Repair Procedures Additional Coverage: Diagnosis, Servicing, Troubleshooting Page Count Estimated Page Count: Approximately 1500-2000 (typical for full factory service manuals) Manual Type Type: Factory Service/Repair/Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Cooling System, Exhaust System, Transmission, Drivetrain Chassis: Suspension, Steering, Brakes, Wheels, Tires, Frame Electrical: Battery, Starting, Charging, Ignition, Lighting, Instrumentation, Body Electrical, Powertrain Control Module (PCM), Chassis Control Module (CCM), Audio System, HVAC Controls Body: Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System Emission Control: Emission Control Systems, Diagnosis and Repair Wiring Diagrams: Comprehensive electrical wiring diagrams are included, crucial for troubleshooting the vehicle's complex electrical systems. Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements, Inspections Repair: Component Removal, Installation, Overhaul, and Adjustment Diagnosis: Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Symptom-based Diagnosis Technical Data: Specifications, Tolerances, Torque Values, Wiring Diagrams Engine Rebuild: Detailed instructions for engine disassembly, inspection, repair, and reassembly, including piston ring replacement, bearing services, and cylinder head work. Transmission Repair: Procedures for transmission removal, disassembly, component replacement (e.g., clutch packs, torque converter), and reassembly. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced engine and transmission rebuilds, electrical system diagnostics, and chassis repairs. Diagnostic Tools: Information on using diagnostic scan tools (OBD-II) for retrieving and interpreting diagnostic trouble codes (DTCs). 📊 Manual Specifications File Format Format: PDF Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader, WinZip (for initial download if compressed) Print Quality Printability: All pages are printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: G6CU (V6), J3 (Diesel) Engine Type Gasoline: 3.5L V6 DOHC (24-valve) Engine Displacement Gasoline: 3497 cc (213.4 cu in) Horsepower Gasoline: 194 hp @ 5000 rpm (approximate) Torque Gasoline: 210 lb-ft @ 3500 rpm (approximate) Engine Type Diesel: 2.9L (2891 cc) 4-cylinder Turbo Diesel (Intercooled) Horsepower Diesel: 147 hp @ 3800 rpm (approximate) Torque Diesel: 230 lb-ft @ 2000 rpm (approximate) Performance Acceleration 0 60 Mph: Approx. 9.5-10.5 seconds (V6 gasoline) Fuel Economy Mpg Combined: Approx. 15-18 MPG (V6 gasoline, varies with drivetrain and driving conditions) Fuel System Fuel Delivery Gasoline: Electronic Fuel Injection (MPI) Fuel Type Gasoline: Unleaded Regular Gasoline Fuel Type Diesel: Diesel Fuel 🔧 Transmission Standard Type Gasoline: 4-speed Automatic Optional Type Diesel: 5-speed Manual Type Gasoline: 5-speed Manual (less common for US market) Features Transfer Case 4Wd: Electronically controlled 2-speed transfer case with shift-on-the-fly capability (for 4WD models) Transmission Fluid Spec: SPII-ATF or equivalent (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Length: Approx. 187.6 inches (4765 mm) Width: Approx. 73.2 inches (1859 mm) Height: Approx. 69.3 inches (1760 mm) Wheelbase: Approx. 106.3 inches (2700 mm) Ground Clearance: Approx. 8.0 inches (203 mm) Weights Curb Weight Approx: 4200-4600 lbs (1905-2087 kg) depending on configuration Towing Capacity Max Lbs: Approx. 5000 lbs (2268 kg) (when properly equipped) Payload Capacity Approx Lbs: Approx. 1000-1200 lbs (454-544 kg) 🛡️ Safety Features Ratings NHTSA Rollover Rating 2Wd: 3-star (typically for 2WD models) NHTSA Rollover Rating 4Wd: 4-star (typically for 4WD models) Active Features ABS: Standard on most trims Traction Control: Optional or standard on higher trims Passive Features Airbags: Driver and front passenger airbags Seatbelts: 3-point front and rear seatbelts 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, and optional premium sound system with amplifier and subwoofer. Available steering wheel audio controls on higher trims. Driver Assistance Cruise Control: Standard on most trims Parking Assistance: Rear parking assist sensors were available on some later models. Connectivity Auxiliary Input: Not standard; aftermarket solutions often required for modern audio connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km) or 6 months (refer to manual for exact mileage and oil type). Air Filter Replacement Interval: Every 15,000-30,000 miles (24,000-48,000 km), depending on driving conditions. Spark Plug Replacement Interval: Approx. 60,000-100,000 miles (96,000-160,000 km) for iridium plugs, refer to manual for specific type and interval. Fluid Specifications Engine Oil Type: API SJ or higher, SAE 5W-30 or 5W-40 (check manual for specific viscosity based on temperature). Coolant Type: Ethylene glycol-based...
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2002 Hyundai Terracan Factory Service/Repair/ Workshop Manual
🏷️ Basic Information
Identification
Make:
Hyundai
Model:
Terracan
Year:
2002
Codes
Vin Prefix Common:
KNACP
👋 Introduction
Market Position
Segment:
Mid-size SUV
Segment Description:
The Hyundai Terracan was positioned as a body-on-frame, rugged SUV, competing with vehicles like the Toyota 4Runner, Mitsubishi Montero Sport, and Nissan Pathfinder.
Competitive Analysis
Key Competitors 2002:
Toyota 4Runner, Mitsubishi Montero Sport, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee
Key Features
Body Construction:
Body-on-frame chassis for durability and off-road capability
Drivetrain Options:
Available in 2WD and 4WD (often with electronic transfer case and low-range gearing)
Target Audience:
Consumers seeking a capable, practical SUV for family use, towing, and light to moderate off-roading.
📋 Manual Details
Coverage Areas
Primary Coverage:
Maintenance and Repair Procedures
Additional Coverage:
Diagnosis, Servicing, Troubleshooting
Page Count
Estimated Page Count:
Approximately 1500-2000 (typical for full factory service manuals)
Manual Type
Type:
Factory Service/Repair/Workshop Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Cooling System, Exhaust System, Transmission, Drivetrain
Chassis:
Suspension, Steering, Brakes, Wheels, Tires, Frame
Electrical:
Battery, Starting, Charging, Ignition, Lighting, Instrumentation, Body Electrical, Powertrain Control Module (PCM), Chassis Control Module (CCM), Audio System, HVAC Controls
Body:
Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System
Emission Control:
Emission Control Systems, Diagnosis and Repair
Wiring Diagrams:
Comprehensive electrical wiring diagrams are included, crucial for troubleshooting the vehicle's complex electrical systems.
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Inspections
Repair:
Component Removal, Installation, Overhaul, and Adjustment
Diagnosis:
Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Symptom-based Diagnosis
Technical Data:
Specifications, Tolerances, Torque Values, Wiring Diagrams
Engine Rebuild:
Detailed instructions for engine disassembly, inspection, repair, and reassembly, including piston ring replacement, bearing services, and cylinder head work.
Transmission Repair:
Procedures for transmission removal, disassembly, component replacement (e.g., clutch packs, torque converter), and reassembly.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to advanced engine and transmission rebuilds, electrical system diagnostics, and chassis repairs.
Diagnostic Tools:
Information on using diagnostic scan tools (OBD-II) for retrieving and interpreting diagnostic trouble codes (DTCs).
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader, WinZip (for initial download if compressed)
Print Quality
Printability:
All pages are printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
G6CU (V6), J3 (Diesel)
Engine Type Gasoline:
3.5L V6 DOHC (24-valve)
Engine Displacement Gasoline:
3497 cc (213.4 cu in)
Horsepower Gasoline:
194 hp @ 5000 rpm (approximate)
Torque Gasoline:
210 lb-ft @ 3500 rpm (approximate)
Engine Type Diesel:
2.9L (2891 cc) 4-cylinder Turbo Diesel (Intercooled)
Horsepower Diesel:
147 hp @ 3800 rpm (approximate)
Torque Diesel:
230 lb-ft @ 2000 rpm (approximate)
Performance
Acceleration 0 60 Mph:
Approx. 9.5-10.5 seconds (V6 gasoline)
Fuel Economy Mpg Combined:
Approx. 15-18 MPG (V6 gasoline, varies with drivetrain and driving conditions)
Fuel System
Fuel Delivery Gasoline:
Electronic Fuel Injection (MPI)
Fuel Type Gasoline:
Unleaded Regular Gasoline
Fuel Type Diesel:
Diesel Fuel
🔧 Transmission
Standard
Type Gasoline:
4-speed Automatic
Optional
Type Diesel:
5-speed Manual
Type Gasoline:
5-speed Manual (less common for US market)
Features
Transfer Case 4Wd:
Electronically controlled 2-speed transfer case with shift-on-the-fly capability (for 4WD models)
Transmission Fluid Spec:
SPII-ATF or equivalent (refer to manual for exact specification and capacity)
📐 Dimensions
Exterior
Length:
Approx. 187.6 inches (4765 mm)
Width:
Approx. 73.2 inches (1859 mm)
Height:
Approx. 69.3 inches (1760 mm)
Wheelbase:
Approx. 106.3 inches (2700 mm)
Ground Clearance:
Approx. 8.0 inches (203 mm)
Weights
Curb Weight Approx:
4200-4600 lbs (1905-2087 kg) depending on configuration
Towing Capacity Max Lbs:
Approx. 5000 lbs (2268 kg) (when properly equipped)
Payload Capacity Approx Lbs:
Approx. 1000-1200 lbs (454-544 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating 2Wd:
3-star (typically for 2WD models)
NHTSA Rollover Rating 4Wd:
4-star (typically for 4WD models)
Active Features
ABS:
Standard on most trims
Traction Control:
Optional or standard on higher trims
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
3-point front and rear seatbelts
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, and optional premium sound system with amplifier and subwoofer. Available steering wheel audio controls on higher trims.
Driver Assistance
Cruise Control:
Standard on most trims
Parking Assistance:
Rear parking assist sensors were available on some later models.
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions often required for modern audio connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months (refer to manual for exact mileage and oil type).
Air Filter Replacement Interval:
Every 15,000-30,000 miles (24,000-48,000 km), depending on driving conditions.
Spark Plug Replacement Interval:
Approx. 60,000-100,000 miles (96,000-160,000 km) for iridium plugs, refer to manual for specific type and interval.
Fluid Specifications
Engine Oil Type:
API SJ or higher, SAE 5W-30 or 5W-40 (check manual for specific viscosity based on temperature).
Coolant Type:
Ethylene glycol-based antifreeze (typically OAT or HOAT, refer to manual for specific type and mix ratio).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual).
Power Steering Fluid Type:
Power Steering Fluid (PSF) – refer to manual for specific type.
Known Issues
Engine Performance Notes:
Some owners report occasional issues with throttle body sensors or minor oil leaks in higher mileage V6 engines. Diesel models can experience issues related to injection pump or turbocharger seals.
Transmission Notes:
Automatic transmissions are generally robust, but fluid changes are critical to longevity. Manual transmissions can experience clutch wear over time.
Suspension Notes:
Front suspension components (ball joints, bushings) can wear due to the vehicle's weight and off-road use. Rear leaf springs can sag over time.
Electrical Notes:
Common electrical issues can include alternator problems, window regulator failures, and sensor malfunctions.
Body Notes:
Potential for rust on the frame and body panels in areas with harsh winters or high salt exposure. Door seals and weather stripping can degrade over time.
📚 Vehicle History
Brand Heritage
Brand Focus:
Hyundai is a South Korean multinational automotive manufacturer known for producing a wide range of vehicles, including budget-friendly sedans, SUVs, and more recently, premium offerings and EVs.
Model Evolution
Generation Start Year:
2001
Generation End Year:
2006
Platform Basis:
Based on the Mitsubishi Pajero/Montero Sport platform (developed in partnership with Mitsubishi).
Production
Manufacturing Location:
South Korea
🏆 Awards & Recognition
Recognitions
Award History:
The Terracan generally did not receive major awards, but was recognized for its value and capability in its segment.
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