engine HYUNDAI I20 2015 Owners Manual

1.$
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Diesel Engine
Never work on injection system
with engine running or within 30
seconds after shutting of f engine.
High-pressure pump, rail, injectors
and high-pressure pipes are sub-
ject to high pressure eve n after
the engine stopped. The fuel jet
produced by fuel leaks may cause
serious injury, if it touches the
body. People using pacemakers
should not move more than 30cm
closer to the ECU or wiring har-
ness wi thin the engine room while
engine is running, since the high
currents in the electronic engine
control s ystem produce consider-
able magnetic fields.
WARNING
(Continued)
• When you remove the interior trim cover with a flat head (-) driver, be
careful not to dama ge the cover.
• Be careful when you replace and clean bulbs to avoid burns or elec-
trical shock.
Engine compartment precautions
(Diesel engine)• The injector operates at high volt-
age (maximum 200v). Therefore,
the following accidents may occur.
- Direct contact with the injector orinjector wiring may cause electric
shock or damage your muscle or
nerve system.
- The electromagnetic wave from the operating injector may cause
the artificial heart pacemaker to
malfunction.
• Follow the safety tips provided below, when you are checking the
engine room while the engine is
running.
- Do not touch the injector, injectorwirings, and the engine computer
while the engine is running.
- Do not remove the injector con- nector while the engine is run-
ning.
- People using pacemakers must not go near the engine while the
engine is starting or running.

"$# !"$" "$#The following lists are vehicle checks
and inspections that should be per-
formed at the frequencies indicated
to help ensure safe, dependable
operation of your vehicle.
Any adverse conditions should be
brought to the attention of your deal-
er as soon as possible.
These Owner Maintenance Checks
are generally not covered by war-
ranties and you may be charged for
labor, parts and lubricants used.
Owner maintenance schedule When you stop for fuel:• Check the engine oil level.
• Check the coolant level in coolant
reservoir.
• Check the windshield washer fluid level.
• Look for low or under-inflated tires.
• Check the radiator and condenser. Check if the front of the radiator
and condenser are clean and not
blocked with leaves, dirt or insects
etc.
If any of the above parts areextremely dirty or you are not sure
of their condition, we recommend
that you contact an authorized
HYUNDAI dealer.
While operating your vehicle:• Note any changes in the sound of the exhaust or any smell of
exhaust fumes in the vehicle.
• Check for vibrations in the steering wheel. Notice any increased steer-
ing effort or looseness in the steer-
ing wheel, or change in its straight-
ahead position.
• Notice if your vehicle constantly turns slightly or "pulls" to one side
when traveling on smooth, level
road.
• When stopping, listen and check for unusual sounds, pulling to one
side, increased brake pedal travel
or "hard-to-push" brake pedal.
• If any slipping or changes in the operation of your transaxle occurs,
check the transaxle fluid level.
• Check Continuously Variable Transaxle P (Park) function.
• Check the parking brake.
• Check for fluid leaks under your vehicle (water dripping from the air
conditioning system during or after
use is normal).
1.',204/3424-3
Be careful when checking your
engine coolant level when the
engine is hot. Scalding hot coolant
and stea m may blow out under
pressure. This could cause burns
or other serious injury.
WARNING

AAt least monthly:• Check the coolant level in theengine coolant reservoir.
• Check the operation of all exterior lights, including the stoplights, turn
signals and hazard warning flash-
ers.
• Check the inflation pressures of all tires including the spare for tires
that are worn, show uneven wear,
or are damaged.
• Check for loose wheel lug nuts.
At least twice a year (i.e., every Spring and Fall):• Check the radiator, heater and air
conditioning hoses for leaks or
damage.
• Check the windshield washer spray and wiper operation. Clean
wiper blades with clean cloth
dampened with washer fluid.
• Check the headlight alignment.
• Check the muffler, exhaust pipes, shields and clamps.
• Check the lap/shoulder belts for wear and function.
At least once a year:• Clean the body and door drainholes.
• Lubricate the door hinges and checks, and hood hinges.
• Lubricate the door and hood locks and latches.
• Lubricate the door rubber weather- strips.
• Check the air conditioning system.
• Inspect and lubricate Continuously Variable Transaxle linkage and
controls.
• Clean the battery and terminals.
• Check the brake/clutch fluid level.
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$$# !"$" "$#$!$##1.&,204/3424-3
Follow Normal Maintenance Schedule if the vehicle is usually oper ated where none of the following conditions apply.
If any of the following conditions apply, you must follow the Maintenance Under Severe Usage Conditions.
• Repeated driving short distance of less than 8 km (5 miles) in normal temperature or less than 16 km(10 miles) in freezing temperature
• Extensive engine idling or low speed driving for long distance s
• Driving on rough, dusty, muddy, unpaved, graveled or salt-spre ad roads
• Driving in areas using salt or other corrosive materials or in very cold weather
• Driving in the condition of inflowing sand or dust into engine
• Driving in heavy traffic area
• Driving on uphill, downhill, or mountain road repeatedly
• Towing a trailer or using a camper, or roof rack
• Driving as a patrol car, taxi, other commercial use of vehicle towing
• Driving over 170 km/h (106 mile/h)
• Frequently driving in stop-and-go conditionIf your vehicle is operated under the above conditions, you should inspect, replace or refill more frequently than the following Normal Maintenance Schedule. After the periods or distance shown in the chart, continue to follow the pre- scribed maintenance intervals.

1.%),204/3424-3$$ " !"##$$# !"$" "$#!$Engine oil and filterThe 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.Drive beltsInspect all drive belts for evidence of
cuts, cracks, excessive wear or oil
saturation and replace if necessary.
Drive belts should be checked peri-
odically for proper tension and
adjusted as necessary.When you are inspecting the belt,
place the ignition switch in the
LOCK/OFF or ACC position.
Fuel filterA clogged filter can limit the speed at
which the vehicle may be driven,
damage the emission system and
cause multiple issues such as hard
starting. If an excessive amount of
foreign matter accumulates in the
fuel tank, the filter may require
replacement more frequently.
After installing a new filter, run the
engine for several minutes, and
check for leaks at the connections.
We recommend that the fuel filter be
replaced by an authorized HYUNDAI
dealer.
Fuel lines, fuel hoses and con-
nectionsCheck the fuel lines, fuel hoses and
connections for leakage and dam-
age. We recommend that the fuel
lines, fuel hoses and connections be
replaced by an authorized HYUNDAI
dealer.
NOTICE
Diesel only
Never work on injection system
with engine running or within 30
seconds after shutting off engine.
High pressure pump, rail, injectors
and high pressure pipes are sub-
ject to high pressure even a fter
the engine stopped. The fuel jet
produced by fuel leaks may cause
serious injury, if it touch the b ody.
People using pacemakers should
not move than 30cm closer to the
ECU or wiring harness within the
eng ine room while engine is run-
ning, since the high currents in the
Common Rail system produce
considerab le magnetic fields.
WARNING

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VVapor hose and fuel filler capThe vapor hose and fuel filler cap
should be inspected at those inter-
vals specified in the maintenance
schedule. Make sure that a new
vapor hose or fuel filler cap is cor-
rectly replaced.
Vacuum crankcase ventilation
hoses (if equipped)Inspect the surface of hoses for evi-
dence of heat and/or mechanical
damage. Hard and brittle rubber,
cracking, tears, cuts, abrasions, and
excessive swelling indicate deterio-
ration. Particular 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 con-
tact with any heat source, sharp
edges or moving 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 pres-
ent. Hoses should be replaced
immediately if there is any evidence
of deterioration or damage.
Air cleaner filterWe recommend that the air cleaner
filter be replaced by an authorized
HYUNDAI dealer.Spark plugsMake sure to install new spark plugs
of the correct heat range.Do not disconnect and inspect
spark plugs when the engine is
hot. You may burn yourself.
WARNING

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PParking brakeInspect the parking brake system
including the parking brake pedal
and cables. Brake discs, pads, calipers and
rotorsCheck the pads for excessive wear,
discs for run out and wear, and
calipers for fluid leakage.Suspension mounting boltsCheck the suspension connections
for looseness or damage. Retighten
to the specified torque.
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 damage. Replace any damaged
parts.
Drive shafts and bootsCheck the drive shafts, boots and
clamps for cracks, deterioration, or
damage. Replace any damaged
parts and, if necessary, repack the
grease.Air conditioning refrigerant
(if equipped)Check the air conditioning lines and
connections for leakage and dam-
age.

1.%',204/3424-3$$"!"$#!Checking the engine oil level
(Petrol engiene)1.Be sure the vehicle is on level
ground.
2.Start the engine and allow it to reach normal operating tempera-
ture.
3.Turn the engine off and wait for a few minutes (about 5 minutes) for
the oil to return to the oil pan.
4.Pull the dipstick out, wipe it clean, and reinsert it fully.
5.Pull the dipstick out again and check the level. The level should be
between F (Full) and L (Low). If it is near or at L (Low), add enough
oil to bring the level to F (Full).
Do not
overfill.
Use a funnel to help prevent oil from
being spilled on engine components.
Use only the specified engine oil. (Refer to "Recommended lubricantsand capacities" in chapter 8.)
Radiator hose
Be very careful not to touch the
radiator hose when checking or
adding the engine oil as i t may be
hot enough to burn you.
WARNING
OIB074004
OIB074006
•
Do not overfill the engine oil. It
may damage the engine.
•
Do not spill engine oil, when
adding or changing engine oil. If
you drop the engine oil on the
engine ro om, wipe it off immedi-
ately.
•
When you wipe the oil level
gauge, you should wipe it with a
clean cloth. When mixed with
debris, it can cause engine dam-
age.
CAUTION

1.+),204/3424-3CChanging the coolantWe recommend that the coolant be
replaced by an authorized HYUNDAI
dealer.Put a thick cloth or fabric around the
radiator cap before refilling the
coolant in order to prevent the
coolant from overflowing into engine
parts such as the alternator.NOTICE
Coolant•
Do not use radiator coolant or
antifreeze in the washer fluid
reservoir.
•
Radiator coolant can severely
obscure visibility when sprayed
on the windshield and may
cause loss of ve hicle control or
damage to paint and body trim.
WARNING

1.+#,204/3424-3D
Do not allow brake/clutch fluid to
contact the vehicle's body paint, as
paint damage will result.
Brake/clutch fluid, which has been
exposed to open air for an extended
time should never be used as its
qualit y cannot be guaranteed. It
should be properly disposed. Don't
put in the wrong kind of fluid. A few
drop s of mineral-based oil, such as
engine oil, in your brake/clutch sys-
tem can damage brake/clutch sys-
t em parts. NOTICE
Brake/clutch fluid
When changing and adding
brake/clutch fluid, handle it care-
fully. Do not let it com e in contact
with your eyes. If brake/clutch fluid
come in contact with your eyes,
immediately flush the m with a
large quantity of fresh tap water.
Have your eyes examined by a
doctor as soon as possible.
WARNING