fuel HYUNDAI I20 2016 Service Manual

"$# !"$" "$#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).
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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

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

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

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!$# "#$$#Tire care For proper maintenance, safety, and
maximum fuel economy, you must
always maintain recommended tire
inflation pressures and stay within
the load limits and weight distribution
recommended for your vehicle. Recommended cold tire inflation
pressures All tire pressures (including the
spare) should be checked when the
tires are cold. “Cold Tires” means the
vehicle has not been driven for at
least three hours or driven less than
1.6 km (one mile).
Recommended pressures must be
maintained for the best ride, top vehi-
cle handling, and minimum tire wear.
For recommended inflation pressure,
refer to “Tire and wheels” in chapter
8. All specifications (sizes and pres-
sures) can be found on a label
attached to the vehicle.
OIB074055
Tire underinflation
Severe underinflation (70 kPa (10
psi) or more) can lead to severe
heat build-up, ca using blowouts,
tread separation and other tire fail-
ures that can result in the loss of
vehicle contro l leading to severe
injury or death. This risk is much
higher on hot days and when driv-
ing for long pe riods at high
speeds.
WARNING

1.(,204/3424-3
•• Underinflation also results in
excessive wear, poor handling and
reduced fuel economy. Wheel
deformatio n also is possible. Keep
your tire pressures at the proper
levels. If a tire frequently needs
refilling, we recommend that the
system be checked by an author-
ized HYUNDAI dealer.
• Overinflation produces a harsh ride, excessive wear at the center
of the tire tread, and a greater pos-
sibility of damage from roa d haz-
ards. • Warm tires normally exceed rec-
ommended cold tire pressures by
28 to 41 kPa (4 to 6 psi). Do not
release air from warm tires to
adjust the pressure or the tires will
be underinflated.
• Be sure to reinstall the tire inflation
valve caps. Without the valve cap,
dirt or moisture could get into the
val ve core and cause air leakage.
If a valve cap is missing, install a
new one as soon as possible. - Tire
pressure
Always observe the following:
• Check tire pressure when the tires are cold. (After vehicle has been
parked for at least three hours or
hasn't been driven more than 1.6
km (one mile) since startup.)
• C heck the pressure of your spare
tire each time you check the pres-
sure of other tires.
• Never overload your vehicle. Be
careful not to overload a vehicle
luggage rack if your vehicle is
equipped with one.
• Worn, old tires can cause acci-
dents. If your tread is badly worn,
or if your tires have been dam-
aged , replace them.
NOTICE
NOTICE
NOTICE
Tire Inflation
Overinflation or underinflation can
reduce tire life, adversely affect
vehicle handling, and lead to sud-
den tire failure. This could result in
loss of vehicle control and poten-
tial injury.
WARNING

1.#',204/3424-3
FFuse Name
Symbol
Fuse rating
Circuit Protected
SENSOR
10A
Diesel 1.4 : Fuel Filter Warning Sensor
MODULE3
10A
A/C Control Module, E/R Junction Block (Multipurpose Check Conn ector), ATM Shift
Lever ILL., Center Facia Switch, Audio
PDM1
25A
Smart Key Control Module
PDM2
10A
Smart Key Control Module, Start/Stop Button Switch
MODULE2
10A
Parking Distance Warning Buzzer, Parking Distance Warning-Reverse LH/RH, Parking
Distance Warning-Reverse (CENTER) LH/RH
TCU
15A
CVT : Transaxle Range Switch, Pulse Generator 'A' / 'B',
M/T : Vehicle Speed Sensor, I/P Junction Block (Fuse - F26)
TA I L L P R H
RH
10A
Rear Combination Lamp (In/Out) RH, Head Lamp RH, ILL. (+), License Lamp (4DR),
License Lamp LH/RH (5DR)
TA I L L P L H
LH
10A
Rear Combination Lamp (In/Out) LH, Head Lamp LH, License Lamp
RR WIPER
15A
Rear Wiper Motor, PCB Block (Rear Wiper Relay)
ABS
10A
ABS Control Module
A/BAG
10A
SRS Control Module
ECU
10A
PCM/ECM, Smart Key Control Module
BRAKE SWITCH
10A
Stop Lamp Switch, Smart Key Control Module
CLUSTER
10A
Instrument Cluster
Driver’s side fuse panel

1.$%,204/3424-3[ ] : MFR (Multi Focus Reflector) Headlight
( ) : Bi-Function Projection HeadlightPCB Block (Gasoline engine)FF use Name
Symbol
Fuse rating
Circuit Protected
ECU 1
30A
PCB Block (Engine Control Relay, Fuse - F25)
HORN
15A
Horn Relay, B/Alarm Horn Relay
FUEL PUMP
20A
F/Pump Relay
WIPER FRT
25A
Wiper Lo Relay
DRL
(10A)
DRL Relay
H/LAMP LO
20A
H/Lamp Lo Relay
H/LAMP HI
[20A] (10A)
H/Lamp Hi Relay
C/FAN
40A
C/Fan Lo Relay, C/Fan Hi Relay
BLOWER
50A
Blower Relay
IG 2
30A
Start Relay, W/O Button Start : Ignition Switch, With Button St art : PDM Relay Box (IG2 Relay)
B+2
30A
I/P Junction Block (P/WDW Relay, TAIL Relay, Fuse - F1)
TCU 1
10A
1.2 CVT : PCM
ECU 3
15A
F/Pump Relay, ECM, C/Fan HI/LO Relay, Camshaft Position Sensor #1/#2, Oxygen Sensor
(Up/Down), Oil Control Valve #1/#2, Purge Control Solenoid Valve, Variable Intake Solenoid
Valve, A/CON Relay, Immobilizer Module
B/UP LAMP
B/UP
LAMP
10A
CVT : PCM, Transaxle Range Switch, Instrument Cluster, Audio
M/T : Back-Up Lamp Switch, I/P Junction Block (Fuse - F26)

1.$(
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PCB Block (Diesel engine)FFuse Name
Symbol
Fuse rating
Circuit Protected
ECU 4
20A
ECM
ECU 2
15A
E/R Junction Block (RLY. 1), Electrical EGR Control Valve, Mass Air Flow Sensor,
WGT Control Solenoid Valve, Camshaft Position Sensor, Immobilizer Module
ECU 5
10A
Fuel Pressure Regulator Valve

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BBright-metal maintenance• To remove road tar and insects,use a tar remover, not a scraper or
other sharp object.
• To protect the surfaces of bright- metal parts from corrosion, apply a
coating of wax or chrome preser-
vative and rub to a high luster.
• During winter weather or in coastal areas, cover the bright metal parts
with a heavier coating of wax or
preservative. If necessary, coat the
parts with non-corrosive petroleum
jelly or other protective compound.
Underbody maintenanceCorrosive materials used for ice and
snow removal and dust control may
collect on the underbody. If these
materials are not removed, acceler-
ated rusting can occur on the under-
body parts such as the fuel lines,
frame, floor pan and exhaust system,
even though they have been treated
with rust protection.
Thoroughly flush the vehicle under-
body and wheel openings with luke-
warm or cold water once a month,
after off-road driving and at the end
of each winter. Pay special attention
to these areas because it is difficult
to see all the mud and dirt. It will do
more harm than good to wet down
the road grime without removing it.
The lower edges of the doors, rocker
panels, and frame members have
drain holes that should not clog with
dirt; trapped water in these areas can
cause rusting.
After washing the vehicle, test the
brakes while driving slowly to see
if they have been affected by
wat er. If braking performance is
impaired, dry the brakes by apply-
ing them lightly while maintaining
a sl ow forward speed.
WARNING