fuel pump Hyundai H-100 Truck 2012 Owner's Manual

1FEATURES OF YOUR HYUNDAI
2
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FUEL RECOMMENDATIONS
B010A04HR-GAT Use Diesel
CAUTION:
Do not let any gasoline or water enter the tank. This would make it neces-sary to drain it out and to bleed the lines to avoid jamming the injection pump and damaging the engine.
Diesel fuel Diesel engine must be operated only on commercially available diesel fuel thatcomplies with EN 590 or comparable standard. (EN stands for "European Norm"). Do not use marine diesel fuel,heating oils, or non-approved fuel addi- tives, as this will increase wear and cause damage to the engine and fuelsystem. The use of non-approved fuels and / or fuel additives will result in a limitation of your warranty rights. B010A01HR
Diesel fuel of above cetane 51 is usedin Hyundai vehicle. If two types ofdiesel fuel are available, use summer or winter fuel properly according to the following temperature conditions.
o Above -5°C (23°F) ... Summer type
diesel fuel.
o Below -5°C (23°F) ... Winter type
diesel fuel.
Watch the fuel level in the tank very carefully : If the engine stops through fuel failure, the circuits must be com- pletely purged to permit restarting. Biodiesel Commercially supplied Diesel blends of no more than 7% biodiesel, com- monly 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), veg- etable 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 dam- aged components due to the use of non approved fuels will not be covered by the manufactures warranty.
Biodiesel (for New Zealand) Commercially supplied Diesel blends of no more than 7% biodiesel, com- monly 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), 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.

1FEATURES OF YOUR HYUNDAI
28
B260L02HP-GAT Door Ajar Warning Light and Chime (If Installed)
The door ajar warning light warns you that a door is not completely closed andthe chime warns you that the key is in the ignition switch. NOTE : The warning chime only sounds whenever the key is in the ignitionswitch and the driver's side front door is open simultaneously. The chime sounds until the key is re-moved from the ignition switch or the driver's side front door is closed. B260M01A-AAT Low Fuel Level Warning Light
The low fuel level warning light comes on when the fuel tank is approachingempty. When it comes on, you should add fuel as soon as possible. Driving with the fuel level warning light on orwith the fuel level below "E" can cause the engine to misfire and damage the catalytic converter.
B260N01HR-GAT Malfunction Indicator Light (If Installed)
The MIL(Malfunction Indicator Light) illuminates when there are the malfunc-tions in main sensors(such as pedal sensor, booster sensor, etc.) or FIP(Fuel Injection Pump) during driving.This light will illuminate when the igni- tion key is turned from the "OFF" posi- tion to the "ON" position, and will go outafter the engine starts. If it illuminates while driving, or does not illuminate when the ignition key is turned from the"OFF" position to the "ON" position, take your car to your nearest authorized Hyundai dealer and have the systemchecked. B260E01HP-GAT Seat Belt Warning Light
The seat belt warning light blinks for about 6 seconds when the ignition keyis turned from the "OFF" position to "ON" or "START".B265C01HR-GAT Diesel Preheat Indicator Light
The indicator light illuminates amber when the ignition switch is placed at the"ON" position. The engine can be started after the preheat indicator light goes off. The illuminating time varies with thewater temperature.
NOTE: If the engine were not started within 2 seconds after the preheating is completed, turn the ignition key oncemore to the "LOCK" position during 10 seconds, and then to the "ON" position, in order to preheat again.
Illuminating time (sec)22.5 8 6
0.5 0
Water temperature
(°C)
Below -30 -20-15
60 80

1FEATURES OF YOUR HYUNDAI
30
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B290A02A-AAT ENGINE COOLANT TEMPERA- TURE GAUGE
WARNING:
Never remove the radiator cap when the engine is hot. The engine cool-ant is under pressure and could erupt and cause severe burns. Wait until the engine is cool before re-moving the radiator cap.
The needle on the engine coolant tem-perature gauge should stay in the nor-mal range. If it moves across the dial to "H" (Hot), pull over and stop as soon as possible and turn off the engine. Then open the hood and, after the engine has cooled, check the coolant level and thewater pump drive belt. If you suspect cooling system trouble, have your cool- ing system checked by a Hyundai dealeras soon as possible.
HHR2059
HHR2016
Without Tachometer
With Tachometer
CAUTION:
Avoid driving with a very low fuel level. If you run out of fuel, it could cause the engine to misfire and re-sult in excessive loading of the cata- lytic converter.
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3
WHAT TO DO IN AN EMERGENCY
5
195/70R15C-6PR 155R12C-8PR 195/70R15C-8PR FRONT
290kPa (42PSI)
- - -
!!
SPARE TIRE
WARNING:
Never work on injection system with engine running or within 30 sec- onds after shutting off engine. High pressure pump, rail, injectors andhigh pressure pipes are subject to high pressure even after the engine stopped. The fuel jet produced byfuel leaks may cause serious in- jury, if it touch the body. People using pacemakers should not movethan 30cm closer to the ECU or wiring harness within the engine room while engine is running, sincethe high currents in the Common Rail system produce considerable magnetic fields. WARNING:
Do not remove the radiator cap whenthe engine is hot. This can allowcoolant to be blown out of the open- ing and cause serious burns.
6. If you cannot find the cause of the overheating, wait until the engine temperature has returned to nor-mal. Then, if the engine coolant has been lost, carefully add coolant to the reservoir (Page 6-10) to bringthe fluid level in the reservoir up to the halfway mark.
7. Proceed with caution, keeping alert
for further signs of overheating. Ifoverheating happens again, call a Hyundai dealer for assistance.
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5. If the water pump drive belt is broken
or coolant is leaking out, stop the engine immediately and call the near- est Hyundai dealer for assistance. D040A01HR-GAT The following instructions for the FULL SIZE spare tire should be observed: Check inflation pressure as soon as practical after installing the spare tire, and adjust to the specified pressure. The tire pressure should be periodi-cally checked and maintained at the specified pressure while the tire is stored.
Spare Tire PressureCAUTION:
Serious loss of engine coolant indi- cates there is a leak in the coolingsystem and this should be checked as soon as possible by a Hyundai dealer. TIRE SIZE
TIRE INFLATION
PRESSURE REAR-
340kPa (50PSI)440kPa(64PSI)440kPa (64PSI)
Low Deck (STD)Low Deck (DBL) High Deck

5VEHICLE MAINTENANCE REQUIREMENTS
4
F030A01HR-GAT
Except European Community
The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for
all vehicle services to protect your warranty. Where both kilometers and time are shown, the frequency of service is determined by whichever occurs first.
F030D02HR-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary SCHEDULED MAINTENANCE
NO. 1 2 3 4 5 6 7 8 9
1011 12 13 DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL)ENGINE OIL AND FILTER AIR CLEANER FILTER FUEL FILTER* VALVE CLEARANCE (For 2.6 N/A, 2.5 TCI) INJECTION TIMING (IF EXHAUST GAS INCLUDES BLACK SMOKE) EGR SYSTEM (VALVE, TUBE, HOSE) TIMING BELT (For 2.6 N/A, 2.5 TCI) DRIVE BELT (FOR WATER PUMP AND ALTERNATOR) ENGINE IDLE SPEED FUEL SYSTEM LEAKS INJECTION NOZZLE (IF EXHAUST GAS INCLUDES BLACK SMOKE) VACUUM PUMP AND VACUUM HOSE VACUUM PUMP OIL HOSE
80 64
I
R I I 90 72
R II I I
70 56
I
6048
R I I I I I I
50 40
I
4032
I I I I
30 24
R II I I
20 16
I I I108
I
See Note(1), (2) See Note(3)
Note : (1) 2.6 N/A, 2.5 TCI : For every 5,000 KM or 6 months, whichever occurs first : "R" A2.5 : For every 10,000 KM or 6 months, whichever occurs first : "R"
(2) Republic of South Africa (If the vehicle is lubricated API CH-4 grade or above.): For every 7,500 KM or 6 months, whichever occurs first : "R"
(3) For China, India and Middle East : For every 15,000 KM or 12 months, whichever occurs first : "R" Except China, India and Middle East : For every 45,000 KM or 36 months, whichever occurs first : "R"
(4) Inspect every day. (5) For every 15,000 KM or 12 months, whichever occurs first : "I"
5 4
See Note(4)
KILOMETERS X 1000 MONTHS
See Note(5)
See Note(5)

5VEHICLE MAINTENANCE REQUIREMENTS
6
F040A01HR-GAT
For European Community Only
The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for
all vehicle services to protect your warranty. Where both kilometers and time are shown, the frequency of service is determined by whichever occurs first.
NO. 1 2 3 4 5 6 7 8 9
1011 12 13 DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL) ENGINE OIL AND FILTER AIR CLEANER FILTER FUEL SYSTEM LEAKS FUEL FILTER* VALVE CLEARANCE EGR SYSTEM (VALVE, TUBE, HOSE) INJECTION TIMING (IF EXHAUST GAS INCLUDES BLACK SMOKE) TIMING BELT DRIVE BELT (FOR WATER PUMP/ALTERNATOR) ENGINE IDLE SPEED INJECTION NOZZLE (IF EXHAUST GAS INCLUDES BLACK SMOKE) VACUUM PUMP AND VACUUM HOSE VACUUM PUMP OIL HOSE
75 60
I I I I I 90 72
R
I I
R I I I I I
60 48
I I I I I I I I I
45 36
R
I I I I
30 24
I I I I I I I I
15 12
I I I I I
7.5
6
KILOMETERS X 1000 MONTHS
F040D03HR-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
See Note (5)
Note : (1) For every 7,500 KM or 6 months, whichever occurs first : "R" (2) Inspect every day.
(3) Inspect every 30,000 km or 18 months; replace every 60,000 km or 36 months
(4) This interval depends on fuel quality. It is applicable only when using a qualified fuel, "EN 590 or equivalent". If the diesel fuel specificationsdon't meet the European standards EN590, replace it more frequently. Consult an authorized HYUNDAI dealer for details. In case of
low engine power or fuel pressure decrease of the fuel filter, replace fuel filter immediately regardless of maintenance schedu le.
(5) For every 20,000 KM : "I" See Note (1)
See Note (2)
See Note (3), (4)

5VEHICLE MAINTENANCE REQUIREMENTS
10
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EXPLANATION OF SCHEDULED MAINTENANCE ITEMS
F060M01A-AAT
o Engine Oil and Filter
The engine oil and filter should be
changed at those intervals specified in the maintenance schedule. If the ve- hicle is being driven in severe condi-tions, more frequent oil and filter changes are required.
F060N01HR-GAT
o Valve Clearances
An incorrect valve clearance will not
only result in rough engine operation, but will also cause excessive noiseand reduced engine output.
Inspect valve clearance and adjust as
required while the engine is hot.
See page 9-4 for the valve clearance
description. F060D01TB-GAT
o Fuel Lines, Fuel Hoses and
Connections
Check the fuel lines, fuel hoses and
connections for leakage and damage. Have a trained technician replace any damaged or leaking parts immediately. F060C01A-AAT
o Fuel Filter
A clogged filter can limit the speed at
which the vehicle may be driven, dam- age the emission system and cause hard starting. If an excessive amountof foreign matter accumulates in the fuel tank, the filter may require re- placement more frequently. After installing a new filter, run the
engine for several minutes, and checkfor leaks at the connections. Fuel fil- ters should be installed by trained technicians.
WARNING:
Never work on injection system withengine running or within 30 sec- onds after shutting off engine. High pressure pump, rail, injectors andhigh pressure pipes are subject to high pressure even after the engine stopped. The fuel jet produced byfuel leaks may cause serious injury, if it touch the body. People using pacemakers should not move than30cm closer to the ECU or wiring harness within the engine room while engine is running, since thehigh currents in the Common Rail system produce considerable mag- netic fields.

5
VEHICLE MAINTENANCE REQUIREMENTS
11
F060F01A-AAT
o Vacuum and Crankcase
Ventilation Hoses
Inspect the surface of hoses for evi-
dence of heat and/or mechanical dam- age. Hard and brittle rubber, cracking, tears, cuts, abrasions, and excessiveswelling indicate deterioration. Particu- lar attention should be paid to examin- ing those hose surfaces nearest tohigh heat sources, such as the ex- haust manifold.
Inspect the hose routing to assure that
the hoses do not come in contact withany heat source, sharp edges or mov- ing component which might cause heatdamage or mechanical wear. Inspect all hose connections, such as clamps and couplings, to make sure they aresecure, and that no leaks are present. Hoses should be replaced immedi- ately if there is any evidence of dete-rioration or damage. F060B01HR-GAT
o Drive Belts
Inspect all drive belts (water pump andalternator) for evidence of cuts, cracks, excessive wear or oiliness, and re- place if necessary. Drive belts shouldbe checked periodically for proper ten- sion and adjusted as necessary. F060E01A-GAT
o Timing Belt
Inspect all parts related with the timing
belt for damage and deformation. Re- place any damaged parts immediately.
F060H01A-AAT
o Air Cleaner Filter
A Genuine Hyundai air cleaner filter isrecommended when the filter is re-placed.
F060G01A-AAT
o Vapor Hose and Fuel Filler Cap
The vapor hose and fuel filler cap
should be inspected at those intervals specified in the maintenance sched- ule. Make sure that a new vapor hoseor fuel filler cap is correctly replaced.
F070B01A-GAT
o Cooling System
Check the cooling system part, suchas radiator, coolant reservoir, hoses and connections for leakage and dam- age. Replace any damaged parts. F070C01A-AAT
o Coolant
The coolant should be changed at the intervals specified in the mainte- nance schedule. F070D01HP-GAT
o Manual Transmission Oil Inspect the manual transmission oil according to the maintenance sched- ule. NOTE: If the oil level is low, check for possible leaks before adding oil.Do not overfill.

6 DO-IT-YOURSELF MAINTENANCE
28
G350B01HR-GAT BLEEDING THE FUEL SYSTEM
The fuel system should be bled to remove air as described in the illustra-tion if the fuel supply is exhausted during travel, when the fuel filter is replaced, or if the vehicle is not used fora long time.
1. Loosen the air plug at the upper part of the fuel filter.
NOTE: The fuel filter is located under the driver's seat. To bleed the fuel sys- tem, first tilt the driver's seatback forward. (Refer to "To Inspect theEngine Compartment Under the Driver's Seat." on page 1-12.) HHR4046
2. Pump the hand pump until there are
no more bubbles in the fuel coming out of the air plug. When doing this,place a cloth around the air plug to prevent the escaping fuel from spew- ing about.
3. Tighten the air plug when there are no more bubbles in the fuel.
4. Continue pumping until the hand
pump becomes stiff.
5. Finally, check to be sure that there is
no leakage of fuel.If in doubt, consult your nearest au- thorized HYUNDAI dealer. HHR4047
FUEL FILTER
G240A01A-AAT POWER STEERING HOSES It is suggested that you check the power steering hose connections for fluid leakage at regular intervals. The power steering hoses should be re-placed if there is severe surface crack- ing, scuffing or worn spots. Deteriora- tion of the hose could cause prema-ture failure.
It is due to a power steering fluidcharacteristic in extremely cold con-ditions. Recommended Fluid Use PSF-3 type fluid NOTE: Do not start the engine when the power steering oil reservoir is empty.

6
DO-IT-YOURSELF MAINTENANCE
29
!WARNING:
o Do not smoke or have any other open flame near the vehicle while bleeding the fuel system.
o Be sure to carefully clean away
any fuel which spilled onto nearbyparts coming out of the air plug, because such accumulations of fuel might ignite and cause a fire. G300A01HR-GAT REMOVAL OF WATER FROM THE FUEL FILTER
HHR4045
If the fuel filter warning light illuminates during driving, it indicates that waterhas accumulated in the fuel filter. If this occurs, remove the water as described below.
1. Loosen the drain plug at the bottom of the fuel filter. HHR4047
2. Operate the hand pump slowly 6 or 7 times in order to force the water out through the drain plug.
3. Tighten the drain plug when water no longer comes out.
4. Loosen the air plug and bleed the air. (Refer to "Bleeding the fuel system")
5. Check to be sure that the warning
light illuminates when the ignition key is turned to "ON", and that it goes off when the engine is started. If in doubt, consult your nearest au-thorized HYUNDAI dealer.