ignition HYUNDAI I20 2016 Repair Manual

IIf the engine stalls while driving• Reduce your speed gradually,
keeping a straight line. Move cau-
tiously off the road to a safe place.
• Turn on your hazard warning flash- er.
• Try to start the engine again. If your vehicle will not start, we recom-
mend that you contact an author-
ized HYUNDAI dealer.If the engine stalls at a cross-
road or crossing If the engine stalls at a crossroad or
crossing, if safe to do so, move the
shift lever to the N (Neutral) position
and then push the vehicle to a safe
location.
• If your vehicle has a manual transaxle not equipped with a igni-
tion lock switch, the vehicle can
move forward by shifting to the
2(second) or 3(third) gear and then
turning the starter without depress-
ing the clutch pedal.
If you have a flat tire while driv-
ing If a tire goes flat while you are driv-
ing:
• Take your foot off the accelerator
pedal and let the vehicle slow
down while driving straight ahead.
Do not apply the brakes immedi-
ately or attempt to pull off the road
as this may cause loss of vehicle
control resulting in an accident.
When the vehicle has slowed to
such a speed that it is safe to do
so, brake carefully and pull off the
road. Drive off the road as far as
possible and park on firm, level
ground. If you are on a divided
highway, do not park in the median
area between the two traffic lanes.
• When the vehicle is stopped, press the hazard warning flasher button,
move the shift lever into P (Park,
for Continuously Variable Transaxle
vehicle) or neutral (for Manual
Transaxle vehicle), apply the park-
ing brake, and place the ignition
switch in the LOCK/OFF position. • Have all passengers get out of the
vehicle. Be sure they all get out on
the side of the vehicle that is away
from traffic.
• When changing a flat tire, follow the instructions provided later in
this chapter.
$#"%"#%% %#
$% $$#
!

$#'#"'"' %'$%'&&&%

Jump starting can be dangerous if
done incorrectly. Follow the jump
starting procedure in this section to
avoid serious injury or damage to
your vehicle. If in doubt about how to
properly jump start your vehicle, we
strongly recommend that you have a
service technician or towing service
do it for you.!" !$#
!
$#'#"'"' %'$%'&&&%
To prevent SERIOUS INJURY or
DEATH to you or bystanders,
always follow these precautions
when working ne ar or handling the
battery:
Always read and follow
instructions carefully when
handling a battery.
Wear e ye protection
designed to protect the
eyes from acid splashes.
Keep all flames, sparks, or
smoking materi als away
from the battery.
Hydrogen is always pres-
ent in battery cells, is high-
ly combustible, and ma y
explode if ignited.
(Continued)
(Continued)
Keep batteries out of
reach of children.
Batteries contain sulfuric
acid which is highly corro-
sive. Do not allow acid to
contact your eyes, skin or
clothing.
If acid gets into your eyes, flush
your eyes with clean water for at
least 15 minutes and get immedi-
ate medical attention. If acid gets
on yo ur skin, thoroughly wash the
area. If you feel pain or a burning
sensation, get medical attention
immedi ately.•
When lifting a plastic-cased bat-
tery, excessive pressure on the
case may cause battery acid to
leak. L ift with a battery carrier or
with your hands on opposite cor-
ners.
•
Do not attempt to jump start
your vehicle if your battery is
frozen.
(Continued)
WARNING
(Continued)•
NEVER attempt to recharge the
battery when the vehicle’s bat-
tery cables are connected to the
battery.
•
The electrical ignition system
works with high voltage. NEVER
touch these components with
the engine run ning or when the
ignition switch is in the ON posi-
tion.
•
Do not allow the (+) and (-)
jumper cables to touch. It may
cause sparks.
•
The battery may rupture or
explode when you jump start
with a low or frozen battery.
•
Never attempt jump start if you
observe cracks, leaks or other
damage on Battery.

!$#'#"'"' %'$%'&&&%
Follow these steps to change your
v ehicle’s tire:
1.Park on a level, firm surface.
2.Move the shift lever into P (Park, for Continuously Variable Transaxle
vehicle) or neutral (for Manual
Transaxle vehicle), apply the park-
ing brake, and place the ignition
switch in the LOCK/OFF position.
3.Press the hazard warning flasher button.
4.Remove the wheel lug nut wrench, jack, jack handle, and spare tire
from the vehicle.
5.Block both the front and rear of the tire diagonally opposite of the tire
you are changing. 6.Loosen the wheel lug nuts counter-
clockwise one turn each in the
order shown above, but do not
remove any lug nuts until the tire
has been raised off of the ground. 7.Place the jack at the designated
jacking position under the frame
closest to the tire you are chang-
ing. The jacking positions are
plates welded to the frame with two
tabs and a raised dot. Never jack
any other position or part of the
vehicle.
OIB067006
OIB067005

!!$#'#"'"' %'$%'&&&%
•• Do not tow the vehicle with 4
wheels on the ground (such as
dinghy towing behind a motorhome
or other m otor vehicle) as this can
seriously damage the
Continuously Variable Transaxle.
• Do not tow the vehicle with the
front wheels on the ground as this
may cause damage to the vehicle.
• Do not tow with sling-type equip-
ment. Use a wheel lift or flatbed
equipment.When towing your vehicle in an
emergency without wheel dollies:
1. Place the ignition switch in the ACC position.
2. Place the shift lever in N (Neutral).
3. Release the parking brake.Failure to place the shift lever in N
(Neutral) when being towed with the
front wheels on the ground can
cause internal damage to the
transaxle.
Removable towing hook 1.Open the trunk, and remove the towing hook from the tool case. 2.Remove the hole cover pressing
the lower part of the cover on the
front bumper.
3.Install the towing hook by turning it clockwise into the hole until it is
fully secured.
4.Remove the towing hook and install the cover after use.
NOTICENOTICE
OIB067013OIB064017
■ 5 Door■Cross

!
$#'#"'"' %'$%'&&&%
EEmergency towing If towing is necessary, we recom-
mend you have it done by an author-
ized HYUNDAI dealer or a commer-
cial tow truck service. If towing service is not available in an
emergency, your vehicle may be
temporarily towed using a cable or
chain secured to the emergency tow-
ing hook at the front (or rear) of the
vehicle.
Use extreme caution when towing
the vehicle with a cable or chain. A
driver must be in the vehicle to steer
it and operate the brakes.
Towing in this manner may be done
only on hard-surfaced roads for a
short distance and at low speeds.
Also, the wheels, axles, power train,
steering and brakes must all be in
good condition. Always follow these emergency tow-
ing precautions:
• Place the ignition switch in the
ACC position so the steering
wheel is not locked.
• Place the shift lever in N (Neutral).
• Release the parking brake.
• Depress the brake pedal with more force than normal since you will
have reduced braking perform-
ance.
• More steering effort will be required because the power steer-
ing system will be disabled.
• Use a vehicle heavier than your own to tow your vehicle.
• The drivers of both vehicles should communicate with each other fre-
quently.
• Before emergency towing, check that the hook is not broken or dam-
aged.
• Fasten the towing cable or chain securely to the hook.
• Do not jerk the hook. Apply steady and even force.
OIB067014OIB064018
■Front
• 5 Door■Front • Cross
OIB067015
■ Rear

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

1.+',204/3424-3$#!$#
#!$$Draining water from fuel filterThe fuel filter for diesel engine plays
an important role of separating water
from fuel and accumulating the water
in its bottom.
If water accumulates in the fuel filter,
the warning light comes on when the
ignition switch is in the ON position.
If this warning light turned
on, we recommend that
the system be serviced by
an authorized HYUNDAI
dealer.If the water accumulated in the fuel
filter is not drained at proper times,
damages to the major parts such as
the fuel system can be caused by water permeation in the fuel filter.
Extracting air from the fuel filterIf you drive until you have no fuel left
or if you replace the fuel filter, be
sure to extract air from the fuel sys-
tem as it makes it difficult to start the
engine.
1. Pump up and down(1) approxi- mately 50 times until the pump is
hard.
2. Extract air from the fuel filter by removing the bolt(2) with a cross-
tip screw driver and reinstall the
bolt(2).
3. Pump up and down(1) approxi- mately 15 times.
4. Extract air from the fuel filter by removing the bolt(2) with a cross-
tip screw driver and reinstall the
bolt(2).
5. Pump up and down(1) approxi- mately 5 times.
Information
Use cloths when you extract air sothat the fuel is not sprayed around.
Clean the fuel around the fuel filter or the injection pump before start-
ing the engine to prevent fire.
Finally, check each part if the fuel is leaking.i
NOTICE
OIB074016

1.)$
,204/3424-3
IIf you connect unauthorized elec-
tronic devices to the battery, the bat-
tery may be discharged. Never use
unauthorized devices.
Battery capacity label ❈ The actual battery label in the vehicle
may differ from the illustration.1. CMF60L-BCI : The HYUNDAI model name of battery
2. 12V : The nominal voltage
3. 60Ah(20HR) : The nominal capac- ity (in Ampere hours)
4. 92RC : The nominal reserve capacity (in min.)
5. 550CCA : The cold-test current in amperes by SAE
6. 440A : The cold-test current in amperes by EN
Battery rechargingYour vehicle has a maintenance-free,
calcium-based battery.
• If the battery becomes dischargedin a short time (because, for exam-
ple, the headlights or interior lights
were left on while the vehicle was
not in use), recharge it by slow
charging (trickle) for 10 hours.
• If the battery gradually discharges because of high electric load while
the vehicle is being used, recharge
it at 20-30A for two hours.
NOTICE
OJD072039
■
Example
(Continued)•
Never attempt to recharge the
battery when the battery cables
are connected.
•
The electrical ignition system
works with high voltage. Never
touch these components with
the engine run ning or the igni-
tion switched on.
Failure to follow the above warn-
ings can result in serious bodily
injury or death.

1.#%,204/3424-3
•• When replacing a blown fuse or
relay with a new one, make sure
the new fuse or relay fits tightly into
the clips. The incomplete fastening
fuse or relay may cause the vehi-
cle wiring and electric systems
da mage and a possible fire.
• Do not remove fuses, relays and terminals fastened with bolts or
nuts. The fu ses, relays and termi-
nals may be fastened incomplete-
ly, and it may cause a possible fire.
If fuses, relays and terminals fas-
tened with bolts or nuts are blown,
consult an authorized HYUNDAI
dealer.
• Do n ot input any other objects
except fuses or relays into
fuse/relay terminals such as a driv-
er or wiring . It may cause contact
failure and system malfunction.
(Continued)(Continued)
• Check the blown fuse with
the fuse
information on the fuse box cover.
• Replace the blown fuse on the same place after turning off the
ignition switch and all electric
switches and disconnecting the
negative battery cable.
Instrument panel fuse replace-
ment1. Turn the ignition switch and all
other switches off.
2. Open the fuse panel cover.
OIB074028

1.#),204/3424-3
IInformation
If the memory fuse is pulled up from
the fuse panel, the warning chime,
audio, clock and interior lamps, etc.,
will not operate. Some items must
be reset after replacement. Refer to
"Battery" in this chapter.
Even though the memory fuse is pulled up, the battery can still be
discharged by operation of the
headlights or other electrical
devices.
Engine compartment panel fuse
replacement1. Turn the ignition switch and all
other switches off.
2. Remove the fuse box cover by pressing the tab and pulling up the
cover.
3. Check the removed fuse; replace it if it is blown. To remove or insert
the fuse, use the fuse puller in the
engine compartment fuse panel.
4. Push in a new fuse of the same rating, and make sure it fits tightly
in the clips. If it fits loosely, we rec-
ommend that you consult an
authorized HYUNDAI dealer.
After checking the fuse panel in the
engine compartment, securely install
the fuse panel cover. If not, electrical
failures may occur from water leak-
ing in.NOTICE
i
OIB074031