stop start HYUNDAI I40 2012 Service Manual

Downloaded from www.Manualslib.com manuals search engine Driving your vehicle
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Turn signals when towing a trailer
When you tow a trailer, your vehicle has
to have a different turn signal flasher and
extra wiring. The green arrows on your
instrument panel will flash whenever you
signal a turn or lane change. Properly
connected, the trailer lights will also flash
to alert other drivers you’re about to turn,
change lanes, or stop.
When towing a trailer, the green arrows
on your instrument panel will flash for
turns even if the bulbs on the trailer are
burned out. Thus, you may think drivers
behind you are seeing your signals
when, in fact, they are not. It is important
to check occasionally to be sure the trail-
er bulbs are still working. You must also
check the lights every time you discon-
nect and then reconnect the wires.
Do not connect a trailer lighting system
directly to your vehicle’s lighting system.
Use only an approved trailer wiring har-
ness.
An authorized HYUNDAI dealer can
assist you in installing the wiring harness.
Driving on grades
Reduce speed and shift to a lower gear
before you start down a long or steep
downgrade. If you don’t shift down, you
might have to use your brakes so much
that they would get hot and no longer
operate efficiently.
On a long uphill grade, shift down and
reduce your speed to around 70 km/h (45
mph) to reduce the possibility of engine
and transaxle overheating.
If your trailer weighs more than the max-
imum trailer weight without trailer brakes
and you have an automatic transaxle,
you should drive in D (Drive) when tow-
ing a trailer.
Operating your vehicle in D (Drive) when
towing a trailer will minimize heat build up
and extend the life of your transaxle.
WARNING
Failure to use an approved trailer
wiring harness could result in dam-
age to the vehicle electrical system
and/or personal injury.
CAUTION
When towing a trailer on steep
grades (in excess of 6%) payclose attention to the engine coolant temperature gauge toensure the engine does not over-heat.
If the needle of the coolant tem-perature gauge moves across thedial towards “130/H (HOT)”, pull over and stop as soon as it is safeto do so, and allow the engine to idle until it cools down. You mayproceed once the engine has cooled sufficiently.
You must decide driving speed depending on trailer weight anduphill grade to reduce the possi-bility of engine and transaxleoverheating.

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When you are ready to leave after park-
ing on a hill
1. With the manual transaxle in Neutral
or automatic transaxle in P (Park),
apply your brakes and hold the brake
pedal down while you:

and

2. Slowly remove your foot from the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the chocks.Maintenance when trailer towing
Your vehicle will need service more often
when you regularly pull a trailer.
Important items to pay particular atten-
tion to include engine oil, automatic
transaxle fluid, axle lubricant and cooling
system fluid. Brake condition is another
important item to frequently check. Each
item is covered in this manual, and the
Index will help you find them quickly. If
you’re trailering, it is a good idea to
review these sections before you start
your trip.
Do not forget to also maintain your trailer
and hitch. Follow the maintenance
schedule that accompanied your trailer
and check it periodically. Preferably, con-
duct the check at the start of each day’s
driving. Most importantly, all hitch nuts
and bolts should be tight.CAUTION
Due to higher load during trailer usage, overheating might occurin hot days or during uphill driv- ing. If the coolant gauge indicatesover-heating, switch off the airconditioner and stop the vehicle in a safe area to cool down theengine.
When towing check transaxle fluid more frequently.
If your vehicle is not equipped with an air conditioner, youshould install a condenser fan toimprove engine performance when towing a trailer.

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What to do in an emergency
IN CASE OF AN EMERGENCY WHILE DRIVING
If the engine stalls at a crossroad
or crossing
If the engine stalls at a crossroad orcrossing, set the shift lever in the N
(Neutral) position and then push the
vehicle to a safe place.
If your vehicle has a manual transaxle not equipped with a ignition lock
switch, the vehicle can move forward
by shifting to the 2(Second) or 3(Third)
gear and then turning the starter with-
out depressing the clutch pedal.
If you have a flat tire while driving
If a tire goes flat while you are driving:
1. Take your foot off the accelerator pedaland let the vehicle slow down while
driving straight ahead. Do not apply the
brakes immediately or attempt to pull
off the road as this may cause a loss of
control. 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.
2. When the vehicle is stopped, turn on your emergency hazard flashers, set
the parking brake and put the transaxle
in P (automatic transaxle) or reverse
(manual transaxle).
3. 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.
4. When changing a flat tire, follow the instruction provided later in this sec-
tion.
If engine stalls while driving
1. Reduce your speed gradually, keeping a straight line. Move cautiously off the
road to a safe place.
2. Turn on your emergency flashers.
3. Try to start the engine again. If your vehicle does not start, contact an
authorized HYUNDAI dealer or seek
other qualified assistance.

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TIRE PRESSURE MONITORING SYSTEM (TPMS) (IF EQUIPPED)
(1) Low tire pressure telltale /
TPMS malfunction indicator
(2) Low tire pressure position telltale (Shown on the LCD display) Each tire, including the spare (if pro-
vided), should be checked monthly
when cold and inflated to the inflation
pressure recommended by the vehi-
cle manufacturer on the vehicle plac-
ard or tire inflation pressure label. (If
your vehicle has tires of a different
size than the size indicated on the
vehicle placard or tire inflation pres-
sure label, you should determine the
proper tire inflation pressure for
those tires.)
As an added safety feature, your
vehicle has been equipped with a tire
pressure monitoring system (TPMS)
that illuminates a low tire pressure
telltale when one or more of your
tires is significantly under-inflated.
Accordingly, when the low tire pres-
sure telltale illuminates, you should
stop and check your tires as soon as
possible, and inflate them to the
proper pressure. Driving on a signifi-
cantly under-inflated tire causes the
tire to overheat and can lead to tire
failure. Under-inflation also reduces
fuel efficiency and tire tread life, and
may affect the vehicle’s handling and
stopping ability. Please note that the TPMS is not a
substitute for proper tire mainte-
nance, and it is the driver’s responsi-
bility to maintain correct tire pres-
sure, even if under-inflation has not
reached the level to trigger illumina-
tion of the TPMS low tire pressure
telltale.
Your vehicle has also been equipped
with a TPMS malfunction indicator to
indicate when the system is not
operating properly. The TPMS mal-
function indicator is combined with
the low tire pressure telltale. When
the system detects a malfunction,
the telltale will flash for approximate-
ly 1 minute and then remain continu-
ously illuminated. This sequence will
continue upon subsequent vehicle
start-ups as long as the malfunction
exists. When the TPMS malfunction
indicator remains illuminated after
blinking for approximately 1 minute,
the system may not be able to detect
or signal low tire pressure as intend-
ed.
OVF061011
OVF061012
■Type A■Type B

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67
Engine compartment precautions
(Diesel engine)
The injector operates at high voltage(maximum 200v). Therefore, the follow-
ing 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 arti-
ficial 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 connector while the engine is running.
- People using pacemakers must not go near the engine while the engine
is starting or running.
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, have it done by an
authorized HYUNDAI dealer.
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.

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Maintenance
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS
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.
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.
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. Fuel filters should be
installed by an authorized HYUNDAI
dealer.
Fuel lines, fuel hoses and con-
nections
Check the fuel lines, fuel hoses and con-
nections for leakage and damage. Have
an authorized HYUNDAI dealer replace
any damaged or leaking parts immedi-
ately.
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.

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Maintenance
No.Fuse ratingSymbol Fuse NameProtected component
1325AP/WDW LHPower Window LH Relay, Power Window Main Switch,
Driver/Passenger Safety Power Window Module,
Rear Safety Power Window Module LH, Rear Power Window Switch LH
1410APDM 1Tail Gate Open Relay, Trunk Lid Latch (SEDAN),
Power Tail Gate Latch/Tail Gate Latch (WAGON),
ICM Relay Box (Fuel Filler Lock/Unlock Relay)
1530AP/SEAT DRVDriver IMS Module, Driver Manual Switch
167.5AMODULE 2
BCM, Immobilizer Module, DC-DC Converter (Audio/AMP), Audio,
Electro Chromic Mirror, Lane Keeping Assist Module, A/C Control Module,
Head Lamp LH/RH, Driver IMS Module, Auto Head Lamp Leveling Device Module,
Portable Lamp, Head Lamp Leveling Device Actuator LH/RH, Rear Seat Warmer LH/RH,
Tire Pressure Monitoring Module, Driver/Passenger CCS Control Module,
ATM Shift Lever IND., Console Switch, Driver/Passenger Seat Warmer Modul
1715AWIPER RRRear Wiper Relay, Rear Wiper Motor, Multifunction Switch, Rear Curtain Module
1810ASTOP LPStop Lamp Switch
1925AP/WDW RHPower Window RH Relay, Power Window Main Switch, Passenger Power Window Switch,
Driver/Passenger Safety Power Window Module, Rear Safety Power Window Module RH,
Rear Power Window Switch RH
2010APDM 2Smart Key Control Module, Start/Stop Button Switch, Immobilizer Module
217.5AMODULE 5Driver/Passenger Smart Key Outside Handle, Driver/Passenger Power Outside Mirror,
Active Air Flap Unit, Rear Seat Warmer Switch LH/RH, Auto Light & Photo Sensor,
Sport Mode Switch, Key Solenoid

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Maintenance
No.Fuse ratingSymbol Protected component
FUSE
1415ARLY. 5 (Horn Relay), ICM Relay Box (Front Deicer Relay)
1515ARLY. 12 (HAC Relay), Stop Signal Relay
1620AICM Relay Box (Head Lamp Washer Relay)
1720AD4FD & A/T : TCM
1840AW/O Button Start : Ignition Switch,
With Button Start : RLY. 8 (PDM 2 (ACC) Relay)/RLY. 10 (PDM 3 (IG1) Relay
1940AEMS Box
2050AI/P Junction Box (Leak Current Autocut Device, Fuse - F18/F25/F30/F34/F38)
2110AA/C Control Module
2210APCM/ECM
2315AA/T - TCM (D4FD), Transaxle Range Switch
2410AM/T - Back-Up Lamp Switch, A/T - Rear Combination Lamp (IN) LH/RH,
Rear Curtain Module, A/V & Navigation Head Unit, Electro Chromic Mirror, IPS Control Module
2515ARLY. 9 (D4FD, Start Relay), ECM/PCM, Air Flow Sensor (D4FD)
2610AESP Control Module

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106
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3. Exhaust emission control
system
The Exhaust Emission Control System is
a highly effective system which controls
exhaust emissions while maintaining
good vehicle performance.
Vehicle modifications
This vehicle should not be modified.
Modification of your vehicle could affect
its performance, safety or durability and
may even violate governmental safety
and emissions regulations.
In addition, damage or performance
problems resulting from any modification
may not be covered under warranty.
If you use unauthorized electronic
devices, it may cause the vehicle to
operate abnormally, wire damage, bat-
tery discharge or fire. For your safety,
do not use unauthorized electric
devices.
Engine exhaust gas precautions (carbon monoxide)
Carbon monoxide can be present with other exhaust fumes. Therefore, if you
smell exhaust fumes of any kind inside
your vehicle, have it inspected and
repaired immediately. If you ever sus-
pect exhaust fumes are coming into
your vehicle, drive it only with all the
windows fully open. Have your vehicle
checked and repaired immediately. Do not operate the engine in confined
or closed areas (such as garages) any
more than what is necessary to move
the vehicle in or out of the area.
When the vehicle is stopped in an open area for more than a short time
with the engine running, adjust the
ventilation system (as needed) to draw
outside air into the vehicle.
Never sit in a parked or stopped vehi- cle for any extended time with the
engine running.
When the engine stalls or fails to start, excessive attempts to restart the
engine may cause damage to the
emission control system.
WARNING- Exhaust
Engine exhaust gases contain car-
bon monoxide (CO). Though color-
less and odorless, it is dangerous
and could be lethal if inhaled.
Follow the instructions following to
avoid CO poisoning.

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Index
Emergency Stop Signal (ESS).....................................5-45
Hill-start assist control (HAC) ....................................5-45
Power brakes ...............................................................5-29
Vehicle stability management......................................5-44
Brakes/clutch fluid .........................................................7-48
Bulb replacement ...........................................................7-85
Bulb wattage ....................................................................8-3
Button start/stop, see engine start/stop button.................5-8
Camera (Rear view) .......................................................4-94
Capacities (Lubricants) ....................................................8-5
Care Exterior care ................................................................7-99
Interior care ...............................................................7-104
Tire care .......................................................................7\
-61
Cargo security screen...................................................4-147
Center console storage .................................................4-136
Central door lock switch................................................4-16
Certification label ............................................................8-8
Chains Tire chains ...................................................................5-70
Changing tires ..................................................................6-9
Checking tire inflation pressure.....................................7-63
Child restraint system ....................................................3-29 ISOFIX system ............................................................3-35 Seat belt .......................................................................3\
-30
Tether anchor system ...................................................3-33
Child-protector rear door lock .......................................4-19
Cigarette lighter ...........................................................4-140
Climate control air filter ......................................4-120, 131
Climate control air filter ................................................7-53
Clothes hanger .............................................................4-144
Combined instrument, see instrument cluster ...............4-48
Compact spare tire .........................................................6-14
Compact spare tire replacement ....................................7-66
Cool box.......................................................................4\
-137
Coolant ........................................................................\
...7-45
Cooling fluid, see engine coolant ..................................7-45
Crankcase emission control system .............................7-105
Cruise control system ....................................................5-48
Cup holder ...................................................................4-141\
Curtain air bag ...............................................................3-54
Dashboard illumination, see instrument panel illumination . ........................................................................\
......................4-49
Dashboard, see instrument cluster .................................4-48
Daytime running light..................................................4-102
Deadlocks.......................................................................4\
-18
Defogging (Windshield) ..............................................4-133
Defroster (Rear window) .............................................4-111
C
D