fuel pump Hyundai H-1 (Grand Starex) 2016 Owner's Manual

15
Introduction
A020202BUN
Biodiesel
Commercially supplied Diesel blends of no
more than 7% biodiesel, commonly known
as "B7 Diesel" may be used in your vehicle
if Biodiesel meets EN 14214 or equivalent
specifications. (EN stands for "European
Norm"). The use of biofuels exceeding 7%
made from rapeseed methyl ester (RME),
fatty acid methyl ester (FAME), vegetable
oil methyl ester (VME) etc. or mixing diesel
exceeding 7% with biodiesel will cause
increased wear or damage to the engine
and fuel system. Repair or replacement of
worn or damaged components due to the
use of non approved fuels will not be cov-
ered by the manufactures warranty.
A020202AUN
Biodiesel (for New Zealand)
Commercially supplied Diesel blends of
no more than 7% biodiesel, commonly
known as "B7 Diesel" may be used in
your vehicle if Biodiesel meets EN 14214
or equivalent specifications. (EN stands
for "European Norm"). The use of biofu-
els exceeding 7%, made from rapeseed
methyl ester (RME), vegetable oil methyl
ester (VME) etc. or mixing diesel exceed-
ing 7% with biodiesel will cause
increased wear or damage to the engine
and fuel system. Repair or replacement
of worn or damaged components due to
the use of non approved fuels will not be
covered by the manufactures warranty.
CAUTION
Do not let any gasoline or water
enter the tank. This would make it
necessary to drain it out and to
bleed the lines to avoid jamming the
injection pump and damaging the
engine.
CAUTION- Diesel Fuel
(if equipped with DPF)
It is recommended to use the regu-
lated automotive diesel fuel for
diesel vehicle equipped with the
DPF system.
If you use diesel fuel including high
sulfur (more than 50 ppm sulfur)
and unspecified additives, it can
cause the DPF system to be dam-
aged and white smoke can be emit-
ted.
CAUTION
• Never use any fuel, whether
diesel, B7 biodiesel or otherwise,
that fails to meet the latest petro-
leum industry specification.
• Never use any fuel additives or
treatments that are not recom-
mended or approved by the vehi-
cle manufacturer.

451
Features of your vehicle
Low brake vacuum pressure warning
(diesel engine only, if equipped)
If the warning light remains on, it may
indicate that the brake vacuum pump has
any problem. Therefore you should avoid
high speed driving or sudden stop, and
you should depress the brake pedal
deeper and harder than usual in braking.
We recommend that the system be serv-
iced by an authorized HYUNDAI dealer.D150312AUN
Shift pattern indicator
(if equipped)
The indicator displays to show the auto-
matic transmission shift lever selection.
Manual transmission shift
indicator (if equipped)
This indicator informs you which gear is
desired while driving to save fuel.
For example
: Indicates that shifting up to the 3rd
gear is desired (currently the shift
lever is in the 2nd gear).
: Indicates that shifting down to the
3rd gear is desired (currently the
shift lever is in the 4th gear).
✽ NOTICE
When the system is not working proper-
ly, up/down arrow indicator and gear is
not displayed.
Automatic transmission
shift indicator
(if equipped, For Europe)
In the Sports Mode, this indicator informs
which gear is desired while driving to
save fuel.
• Shifting up :▲
2, ▲
3, ▲
4, ▲
5*
• Shifting down :
▼1,
▼2,
▼3,
▼4*
* : if equipped
For example
: Indicates that shifting up to the 3rd
gear is desired (currently the shift
lever is in the 2nd or 1st gear).
: Indicates that shifting down to the
3rd gear is desired (currently the
shift lever is in the 4th gear).
When the system is not working properly,
the indicator is not displayed.WARNING
• Continuous braking while driving
on steep or long downhill may
cause to descend the vacuum
level in brake booster for a time
and turn on the warning light. In
this case, shift down the trans-
mission. If the warning light illu-
minate continuously, stop the
vehicle in the safe location and
wait until the warning light goes
off.
• Driving the vehicle with a warn-
ing light on is dangerous. If the
brake warning light remains on,
we recommend that the system
be checked by an authorized
HYUNDAI dealer.

75
Maintenance
G020300ATQ
WARNING- Maintenance
work
• Performing maintenance work on
a vehicle can be dangerous. You
can be seriously injured while
performing some maintenance
procedures. If you lack sufficient
knowledge and experience or the
proper tools and equipment to do
the work, we recommend that the
system be servied by an author-
ized HYUNDAIdealer.
• Working under the hood with the
engine running is dangerous. It
becomes even more dangerous
when you wear jewelry or loose
clothing. These can become
entangled in moving parts and
result in injury. Therefore, if you
must run the engine while work-
ing under the hood, make certain
that you remove all jewelry (espe-
cially rings, bracelets, watches,
and necklaces) and all neckties,
scarves, and similar loose cloth-
ing before getting near the
engine or cooling fans.
WARNING- Diesel Engine
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 after the
engine stopped. The fuel jet pro-
duced by fuel leaks may cause seri-
ous injury, if it touches the body.
People using pacemakers should
not move than 30cm closer to the
ECU or wiring harness within the
engine room while engine is run-
ning, since the high currents in the
electronic engine control system
produce considerable magnetic
fields.
CAUTION
• Do not put heavy objects or apply
excessive force on top of the
engine cover (if equipped) or fuel
related parts.
• When you inspect the fuel system
(fuel lines and fuel injection
devices), we recommend that you
contact an authorized HYUNDAI
dealer.
• Do not drive long time with the
engine cover (if equipped)
removed.
• When checking the engine room,
do not go near fire. Fuel, washer
fluid, etc. are flammable oils that
may cause fire.
• Before touching the battery, igni-
tion cables and electrical wiring,
you should disconnect the bat-
tery "-" terminal. You may get an
electric shock from the electric
current.
• When you remove the interior
trim cover with a flat head (-) driv-
er, be careful not to damage the
cover.
• Be careful when you replace and
clean bulbs to avoid burns or
electrical shock.

Maintenance
10 7
NORMAL MAINTENANCE SCHEDULE (EXCEPT FOR EUROPE A2 2.5 DIESEL ENGINE) (CONT.)
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.
*
4: This maintenance schedule depends on fuel quality. It is applicable only when using a qualified fuel < "EN590 or equivalent">.
If the diesel fuel specification doesn't meet the EN590, it must be replaced more frequently. If there are some important safety
matters like fuel flow restriction, surging, loss of power, hard starting problem etc, replace the fuel filter immediately regardless
of maintenance schedule and we recommend that you consult an authorized HYUNDAI dealer.
*
5: If the diesel fuel specification doesn't meet the EN590, it must be replaced more frequently. HYUNDAI recommends "every
7,500 km
(5,000 miles) inspection, every 15,000 km (10,000 miles) replacement".
Number of months or driving distance, whichever comes first
Months1224364860728496
Miles×1,0001020304050607080
Km×1,000153045607590105120
Vapor hose and fuel filler capII
Vacuum and crankcase ventilation
hosesGasolineIIII
Vacuum hose (for EGR & throttle body) (if equipped)IIIIIIII
Vacuum pump and vaccum hoseDieselIIIIIIII
Vaccum pump oil hoseDieselIIIIIIII
Fuel filter cartridge *4DieselFor EuropeIRIR
Except Europe*5IRIR
MAINTENANCE
INTERVALS
MAINTENANCE
ITEM

711
Maintenance
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.
*
6: The fuel filter is considered to be maintenance free but periodic inspection is recommended for this maintenance schedule
depends on fuel quality. If there are some important safety matters like fuel flow restriction, surging, loss of power, hard start-
ing problem etc, replace the fuel filter immediately regardless of maintenance schedule and we recommend that you consult
an authorized HYUNDAI dealer.
*
7: When adding coolant, use only deionized water or soft water for your vehicle and never mix hard water in the coolant filled at
the factory. An improper coolant mixture can result in serious malfunction or engine damage.
*
8: For your convenience, it can be replaced prior to it's interval when you do maintenance of other items.
NORMAL MAINTENANCE SCHEDULE (EXCEPT FOR EUROPE A2 2.5 DIESEL ENGINE) (CONT.)
MAINTENANCE
INTERVALS
MAINTENANCE
ITEMNumber of months or driving distance, whichever comes first
Months 12 24 36 48 60 72 84 96
Miles×1,000 10 20 30 40 50 60 70 80
Km×1,000 15 30 45 60 75 90 105 120
Fuel filter *
6GasolineFor Europe I IExcept EuropeIRIR
Fuel lines, hoses Diesel I I I I
and connections Gasoline I I
Cooling system
For Europe
Engine coolant *
7
Except Europe
At first, replace at 210,000 km (120,000 miles) or 10 years:
after that, replace every 30,000 km (20,000 miles) or 24 months *
8
At first, replace at 200,000 km (120,000 miles) or 10 years:
after that, replace every 40,000 km (25,000 miles) or 24 months *
8
Inspect “Coolant level and leak” every day
Inspect “Water pump” when replacing the drive belt or timing belt

Maintenance
14 7
G040100ATQ-EU
NORMAL MAINTENANCE SCHEDULE (FOR EUROPE A2 2.5 DIESEL ENGINE) (CONT.)
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.
*
1: Adjust alternator and power steering (and water pump drive belt) and air conditioner drive belt (if equipped). Inspect and if necessary correct
or replace.
*
2: Check the engine oil level and leak every 500 km (350 miles) or before starting a long trip. The engine oil level should be checked regularly and
maintained properly. Operating with an insufficient amount oil can damage the engine, and such damage is not covered by warranty.
*
3: If the recommended oil is not available, replace engine oil and engine oil filter every 20,000 km (12,500 miles) or 12 months.
*4: This maintenance schedule depends on fuel quality. It is applicable only when using a qualified fuel <"EN590 or equivalent">. If the diesel fuel
specification doesn't meet the EN590, it must be replaced according to the severe maintenance schedule.
*
5: This maintenance schedule depends on fuel quality. It is applicable only when using a qualified fuel < "EN590 or equivalent">. If the diesel fuel
specification doesn't meet the EN590, it must be replaced more frequently. If there are some important safety matters like fuel flow restriction,
surging, loss of power, hard starting problem etc, replace the fuel filter immediately regardless of maintenance schedule and we recommend
that you consult an authorized HYUNDAI dealer.
Number of months or driving distance, whichever comes first
Months24487296120144168192
Miles×1,00020406080100120140160
Km×1,000306090120150180210240
Drive Belts *1At first, inspect 90,000 km (60,000 miles) or 48 months
after that, inspect every 30,000 km (20,000 miles) or 24 months
Engine oil and engine oil filter *2*3 *4RRRRRRRR
Air cleaner filterIRIRIRIR
Vapor hose and fuel filter capIIII
Vacuum hose (for EGR & throttle body) (if equipped)IIIIIIII
Vacuum pump and vacuum hoseIIIIIIII
Vacuum pump oil hoseIIIIIIII
Fuel Filter Cateridge *5RRRRRRRR
Fuel line hoses and connectionsInspect every 20,000 km (12,500 miles) or 12months
MAINTENANCE
INTERVALS
MAINTENANCE
ITEM

719
Maintenance
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS
G050100AUN
Engine oil and filter
The 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 fre-
quent oil and filter changes are required.
G050200BUN
Drive belts
Inspect all drive belts for evidence of
cuts, cracks, excessive wear or oil satu-
ration and replace if necessary. Drive
belts should be checked periodically for
proper tension and adjusted as neces-
sary.
G050300ATQ
Fuel filter (cartridge)
A 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 exces-
sive amount of foreign matter accumu-
lates 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 authoized
HYUNDAI dealer.
G050400AEN
Fuel lines, fuel hoses and con-
nections
Check the fuel lines, fuel hoses and con-
nections for leakage and damage. We
recommend that the fuel lines, fuel hoses
and connectionsr be replaced by an
authoized HYUNDAI dealer.
WARNING - 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 after the
engine stopped. The fuel jet pro-
duced by fuel leaks may cause seri-
ous injury, if it touch the body.
People using pacemakers should
not move than 30cm closer to the
ECU or wiring harness within the
engine room while engine is run-
ning, since the high currents in the
Common Rail system produce con-
siderable magnetic fields.
CAUTION
In case the fuel filter is clogged due
to not conforming to the mainte-
nance period, the fuel injection
equipment may supply the fuel
insufficiently, which may damage
the fuel injection equipment and
cause the engine to stall at worst
cases.
CAUTION
When you are inspecting the belt,
place the ignition switch in the
LOCK/OFF or ACC position.

757
Maintenance
Instrument panel fuse panel
Description Fuse rating Protected component
AUDIO-2 10A Audio, Digital clock, BCM, Power outside mirror switch
C/LIGHTER 20A Cigarette lighter, Front power outlet
S/HEATER DRV 10A Driver seat warmer switch (if equipped)
FOG LAMP REAR 10A Rear fog lamp relay
HEAD LAMP 10A Head lamp High/Low relay
WIPER FRT 25A Front wiper relay, Front wiper motor
BCM 10A BCM, DRL
HEATER 10A Front/Rear blower relay, Front/Rear A/C control module, Condenser fan relay, Electro chromic mirror,
Thermo switch, PTC heater relay(D4CB), EGR solenoid valve(D4BH)
B/UP LAMP 10A Back-up lamp relay, Back-up lamp switch, Transmission range switch
ABS 10A ABS/ESC control module, ESC switch(D4CB)
T/SIGNAL LAMP 10A Hazard switch
AIR BAG 10A SRS control module
MODULE 10A Instrument cluster, BCM, Immobilizer control module(D4BH), A/C relay(D4BH), Generator resister
ECU 10A Vehicle speed sensor, ECM, Air flow sensor(D4CB), Injection pump(D4BH), TCM, Fuel filter warning sensor
START 10A Start relay, Burglar alarm relay
HEATED MIRROR 10A Front A/C control module, Power outside mirror & defogger LH/RH
STOP LAMP 15A Stop lamp switch
RPAS 15A Buzzer, Stop, Signal electronic module

759
Maintenance
Engine compartment main fuse panel
Description Fuse rating Protected component
ALT 150A/200A Fuse(A/CON, FRT DEICER), Fusible link(FRT HTR, RR HTR, RR HTD, C/FAN, F/FILTER, ABS 1/2),
Generator, E/R fuse & relay box RH
B+ 1 50A Fuse(DR LOCK, FRT FOG LP, B/ALARM, Power connector(AUDIO-1, ROOM LP))
B+ 2 30A Fuse(FUEL LID, P/WDW LH/RH, HAZARD), Multipurpose check connector
B+ 3/RAD FAN 5 40A Fuse(STOP LP, BWS), Radiator fan relay(G4KC)
IG 1 40A Ignition switch(ACC, IG1)
IG 2 40A Ignition switch(IG2, START), Start relay
ECU 3 30A/20A Engine control relay
HEATER FRT 40A Front blower relay
REAR HEATED 40A Rear defogger relay
HEATER RR 40A Rear blower relay
ABS 1 40A ABS control module(G4KC)
ABS 2 40A ABS control module(G4KC)
COOLING FAN 1 30A Condenser fan relay 1
COOLING FAN 2 30A Radiator Fan Motor
FUEL HEATER 30A Fuel filter heater relay(DIESEL)
ECU 4/TCU 10A TCM, ECM (Gasoline)
HORN 10A Horn relay
HEATER 20A Fuel fired heater control module(D4CB)
FUEL PUMP 15A Fuel pump relay(G4KC)
ALT 10A Generator(D4BH)
H/LAMP HI 15A Head lamp(HIGH) relay, Head lamp(LOW) relay
A/CON 10A A/C relay
DEICER 15A Windshield defogger relay (if equipped)
TAIL LAMP LH 10A Head lamp LH(Position lamp), Rear combi lamp LH, License lamp LH

Maintenance
60 7
Description Fuse rating Protected component
TAIL LAMP RH 10A Head lamp RH(Position lamp), Rear combi lamp RH, License lamp RH
HEAD LAMP LH 10A Head lamp LH
HEAD LAMP RH 10A Head lamp RH
SENSOR 1 10A A/C relay, Condenser fan relay(D4CB), Lambda sensor(D4CB), PTC heater relay #1(D4CB), Stop lamp
switch(D4CB)
SENSOR 2 15A D4CB: Camshaft position sensor, Glow plug relay, EGR actuator, VGT control valve, Immobilizer control module
G4KC: Fuel pump relay, Canister purge solenoid valve, Oil control valve, Crankshaft position sensor,
Oxygen sensor, Immobilizer control module, Idle speed control actuator
IGN COIL 15A Ignition coil #1~#4(G4KC), Condenser(G4KC)
ECU 1 10A ECM(D4CB)
ECU 2 20A ECM(D4CB, G4KC), Injector #1~#4(G4KC)
Engine compartment sub fuse panel (Diesel engine)
Description Fuse rating Protected component
GLOW 80A Glow plug relay
PTC HEATER 1 40A PTC heater relay #1
PTC HEATER 2 40A PTC heater relay #2
PTC HEATER 3 40A PTC heater relay #3
ABS 1 40A ABS/ESC control module
ABS 2 40A ABS/ESC control module
ECU 15A Electronic Control Unit Power
FUEL PUMP 20A Fuel Pump Motor
DCU 1 20A Dosing Control Unit Power 1
DCU 2 20A Dosing Control Unit Power 2
DCU 3 20A Dosing Control Unit Power 3
DCU 60A Dosing Control Unit Main Power