head HYUNDAI I40 2012 Repair Manual

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Inner panel fuse replacement
1. Turn the ignition switch and all other
switches off.
2. Open the fuse panel cover. 3. Pull the suspected fuse straight out.
Use the removal tool provided in the
engine compartment fuse panel.
4. Check the removed fuse; replace it if it is blown.
5. Push in a new fuse of the same rating, and make sure it fits tightly in the clips.
If it fits loosely, consult an authorized
HYUNDAI dealer.
If you do not have a spare, use a fuse of the same rating from a circuit you maynot need for operating the vehicle, such as the cigar lighter fuse.
If the headlights or other electrical com-
ponents do not work and the fuses are
OK, check the fuse block in the engine
compartment. If a fuse is blown, it must
be replaced.
OVF071018OVF071019

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Instrument panel (Driver’s side fuse panel)
No.Fuse ratingSymbol Fuse NameProtected component
120APOWER
OUTLET 2Console Power Outlet, Rear Power Outlet
230APOWER
TAIL GATEPower Tail Gate
310AMODULE 1Smart Key Control Module, BCM, Audio, AMP, JBL AMP, A/V & Navigation Head Unit,
DC-DC Converter (Audio/AMP), Over Head Console Lamp, Parking Guide System,
Power Outside Mirror Switch
410AMODULE 4E/R Fuse & Relay Box (RLY. 12), Stop Lamp Switch, Multipurpose Check Connector,
Active Air Flap Unit, Fuel Filter Warning Sensor (D4FD)
57.5AMODULE 3Smart Key Control Module, BCM, Panorama Sunroof, Rain Sensor,
Driver/Passenger CCS Control Module, ICM Relay Box (Headlamp Washer Relay)
615APOWER
OUTLET 1Front Power Outlet
720AP/SEAT PASSPassenger Manual Switch
810AHTD MIRRDriver/Passenger Power Outside Mirror, ECM/PCM, A/C Control Module
925AAMPAMP, JBL AMP, DC-DC Converter (AMP)
1025AWIPER FRTICM Relay Box (Rain Sensor Relay), Multifunction Switch,
E/R Fuse & Relay Box (RLY. 7), Front Wiper Motor
117.5AA/CONE/R Fuse & Relay Box (RLY. 4), EMS Box (Fuel Heater Relay),
Diesel Box (PTC Heater Relay #2/#3), A/C Control Module
1215ASTEERING
WHEEL HEATERSteering Wheel Heater

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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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No.Fuse ratingSymbol Fuse NameProtected component
2220AIG1E/R Fuse & Relay Box (Fuse - F27, F28, F29, F30, F31)
2310AMODULE 6Instrument Cluster, Front Seat Warmer Switch LH/RH,
Adaptive Front Lighting Module, Electric Parking Brake Module
2410AMDPSEPS Control Module
2520ADR LOCKDoor Lock/Unlock Relay, ICM Relay Box (Dead Lock Relay),
Driver/Passenger Door Lock Actuator, Rear Door Lock Actuator LH/RH
2615AS/HEATER FRTDriver/Passenger CCS Control Module,
Driver/Passenger Seat Warmer Modul
2710AINTERIOR LAMPDriver/Passenger Door Lamp, Overhead Console Lamp, Portable Lamp, Room Lamp,
Glove Box Lamp, Luggage Lamp, Driver/Passenger Foot Lamp, Trunk Room Lamp,
Rear Personal Lamp LH/RH, Vanity Lamp LH/RH
2815AMULTI MEDIAAudio, A/V & Navigation Head Unit, DC-DC Converter (Audio)
2915AA/BAGSRS Control Module
3010ACURTAINRear Curtain Module
317.5AMEMORY 1Instrument Cluster, Tire Pressure Monitoring Module, Rear Curtain Module,
Tilt Sensor, A/C Control Module, BCM, Ultrasonic Instrusion Protection Sensor,
Siren, Driver IMS Module, Power Outside Mirror Switch
327.5AA/BAG INDInstrument Cluster
337.5APDM 3Smart Key Control Module

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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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Maintenance
LIGHT BULBS
Use only the bulbs of the specifiedwattage.
✽
✽ NOTICE
After driving in heavy rain or washing
the vehicle, headlight and taillight lenses
could appear frosty. This condition is
caused by the temperature difference
between the lamp inside and outside.
This is similar to the condensation on
your windows inside your vehicle during
rain and doesn’t indicate a problem with
your vehicle. If the water leaks into the
lamp bulb circuitry, have the vehicle
checked by an authorized HYUNDAI
dealer.
Headlight, position light, turn sig-
nal light and front fog light bulb
replacement
(1) Headlight (Low)
(2) Smart cornering light
(3) Headlight (High)
(4) Front turn signal light
(5) Position light
(6) Dedicated lamp (DRL) (if equipped)
(7) Front fog light (if equipped)
WARNING - Working on
the lights
Prior to working on the light, firmly
apply the parking brake, ensure
that the ignition switch is turned to
the “LOCK” position and turn off
the lights to avoid sudden move-
ment of the vehicle and burning
your fingers or receiving an electric
shock.
CAUTION
Be sure to replace the burned-out
bulb with one of the same wattagerating. Otherwise, it may causedamage to the fuse or electric wiring system.
CAUTION
If you don’t have necessary tools,the correct bulbs and the expertise,consult an authorized HYUNDAIdealer. In many cases, it is difficultto replace vehicle light bulbs because other parts of the vehiclemust be removed before you canget to the bulb. This is especiallytrue if you have to remove the head-light assembly to
get to the bulb(s).
Removing/installingthe headlight
assembly can result in damage to the vehicle.OVF071030

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Headlight (Low/High), smart corner-
ing light and turn signal light
1. Turn off the engine and open the hood.
2. Remove the front bumper.
3. Remove the headlight assembly from the body of the vehicle. If you can reach
the bulb without removing the headlight
assembly, you do not need to do step 2
and 3.
4. Disconnect the power connector(s) from the back of the headlight assem-
bly.
Headlight (Low/High) and
Smart cornering light
5. Remove the headlight bulb cover byturning it counterclockwise.
6. Disconnect the headlight bulb socket- connector.
7. Remove the socket from the assembly by turning the socket counterclockwise
until the tabs on the socket align with
the slots on the assembly.
8. Pull the bulb out of the socket.
9. Insert a new bulb into the socket.
10. Install the socket in the assembly by aligning the tabs on the socket with
the slots in the assembly. Push the
socket into the assembly and turn the
socket clockwise. 11. Connect the headlight bulb socket-
connector.
12. Install the headlight bulb cover by turning it clockwise.
✽ ✽NOTICE
If the headlight aiming adjustment is
necessary after the headlight assembly is
reinstalled, consult an authorized
HYUNDAI dealer.
OVF071056
Smart cornering Low
High

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Maintenance
Turn signal light
Follow the steps 1 to 4 from the previous
page.
5. Remove the socket from the assemblyby turning the socket counterclockwise
until the tabs on the socket align with
the slots on the assembly.
6. Remove the bulb from the socket by pressing it in and rotating it counter-
clockwise until the tabs on the bulb
align with the slots in the socket. Pull
the bulb out of the socket.
7. Insert a new bulb by inserting it into the socket and rotating it until it locks
into place.
8. Install the socket in the assembly by aligning the tabs on the socket with the
slots in the assembly. Push the socket
into the assembly and turn the socket
clockwise.Front fog light bulbs
1. Turn off the engine.
2. Remove the under cover by rotating
the screws.
3. Reach your hand into the back of the front bumper.
4. Disconnect the power connector from the socket.
5. Remove the bulb-socket from the housing by turning the socket counter
clockwise until the tabs on the socket
align with the slots on the housing.
6. Install a new bulb-socket into the hous- ing by aligning the tabs on the socket
with the slots in the housing. Push the
socket into the housing and turn the
socket clockwise.
7. Connect the power connector to the socket.
OHD076046
WARNING- Halogen bulbs
Halogen bulbs contain pressurizedgas that will produce flying pieces
of glass if broken.
Always handle them carefully, and avoid scratches and abrasions. If
the bulbs are lit, avoid contact with
liquids. Never touch the glass with
bare hands. Residual oil may cause
the bulb to overheat and burst
when lit. A bulb should be operated
only when installed in a headlight.
If a bulb is damaged or cracked, replace it immediately and carefully
dispose of it.
Wear eye protection when chang- ing a bulb. Allow the bulb to cool
down before handling it.
OVF071057OVF071058

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Headlight (HID type), position light
and dedicated lamp
If the light bulb does not operate, have
the vehicle checked by an authorized
HYUNDAI dealer.
✽ ✽ NOTICE
HID lamps have superior performance
vs. halogen bulbs. HID lamps are esti-
mated by the manufacturer to last twice
as long or longer than halogen bulbs
depending on their frequency of use.
They will probably require replacement
at some point in the life of the vehicle.
Cycling the headlamps on and off more
than typical use will shorten HID lamps
life. HID lamps do not fail in the same
manner as halogen incandescent lamps.
If a headlamp goes out after a period of
operation but will immediately relight
when the headlamp switch is cycled it is
likely the HID lamp needs to be
replaced. HID lighting components are
more complex than conventional halo-
gen bulbs thus have higher replacement
cost.
Headlight and front fog light aim-
ing (for Europe)
Headlight aiming
1. Inflate the tires to the specified pres-
sure and remove any loads from the
vehicle except the driver, spare tire,
and tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (Vertical lines pass- ing through respective head lamp cen-
ters) and a horizontal line (Horizontal
line passing through center of head
lamps) on the screen.
4. With the head lamp and battery in nor- mal condition, aim the head lamps so
the brightest portion falls on the hori-
zontal and vertical lines.
WARNING - HID Headlight
low beam (if equipped)
Do not attempt to replace or
inspect the low beam (XENON bulb)
due to electric shock danger. If the
low beam (XENON bulb) is not
working, have your vehicle checked
by an authorized HYUNDAI Dealer.
OVF071050

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Maintenance
5. To aim the low beam left or right, turnthe driver (1) clockwise or counter-
clockwise. To aim the low beam up or
down, turn the driver (2) clockwise or
counterclockwise.
To aim the high beam up or down, turnthe driver (3) clockwise or counter-
clockwise. AFLS type
1. Turn off the engine
2. Turn the light switch to the low beam
position.
3. Position the tires straight ahead with the steering wheel.
4. Turn on the engine.
5. Inflate the tires to the specified pres- sure and remove any loads from the
vehicle except the driver, spare tire,
and tools.
6. The vehicle should be placed on a flat floor.
7. Draw vertical lines (Vertical lines pass- ing through respective head lamp cen-
ters) and a horizontal line (Horizontal
line passing through center of head
lamps) on the screen.
8. With the head lamp and battery in nor- mal condition, aim the head lamps so
the brightest portion falls on the hori-
zontal and vertical lines.
9. To aim the low beam left or right, turn the driver (1) clockwise or counter-
clockwise. To aim the low beam up or
down, turn the driver (2) clockwise or
counterclockwise. To aim the high
beam up or down, turn the driver (3)
clockwise or counterclockwise.
Front fog light aiming
The front fog lamp can be aimed as the
same manner of the head lamps aiming.
With the front fog lamps and battery nor-
mal condition, aim the front fog lamps. To
aim the front fog lamp up or down, turn
the driver (1) clockwise or counterclock-
wise.
OVF071051