Hyundai i20 (2016 year). Instruction

MAINTENANCE UNDER SEVERE USAGE CONDITIONS - DIESEL ENGINE

The following items must be serviced more frequently on cars mainly used under severe driving conditions.

Refer to the chart below for the appropriate maintenance intervals.

R : Replace I : Inspect and if necessary, adjust, correct, clean or replace

Maintenance

Maintenance item

Maintenance intervals

Driving condition

operation

A, B, C, F, G,

Engine oil and engine oil filter

Every 5,000 km (3,000 miles) or 6 months

H, I, J, K, L

Replace more frequently

Air cleaner filter

C, E

depending on the condition

Manual transaxle fluid

Every 120,000 km (80,000 miles)

C, D, E, F, G, H, I, K

Inspect more frequently

Steering gear rack, linkage and boots

C, D, E, F, G

depending on the condition

Inspect more frequently

Front suspension ball joints

C, D, E, F, G

depending on the condition

7-21

Maintenance

Maintenance item

Maintenance intervals

Driving condition

operation

Inspect more frequently

Disc brakes and pads, calipers and rotors

C, D, E, G, H

depending on the condition

Inspect more frequently

Parking brake

C, D, G, H

depending on the condition

Inspect more frequently

C, D, E, F, G,

Driveshaft and boots

depending on the condition

H, I, J, K, L

Inspect more frequently

Climate control air filter

C, E

depending on the condition

Severe driving conditions

A:Repeated short distance driving

G:Driving in mountainous areas.

B:Extensive idling

H:Towing a trailer

C:Driving in dusty, rough roads

: Driving for patrol car, taxi, commercial car or vehicle

D:Driving in areas using salt or other corrosive

towing

materials or in very cold weather

J :Driving in very cold weather

E:Driving in sandy areas

K:Driving over 170 km/h (106 mile/h)

F :More than 50% driving in heavy city traffic during hot

L :Frequently driving in stop-and-go conditions

weather above 32 °C (90 °F)

7-22

EXPLANATION OF SCHEDULED MAINTENANCE ITEMS

Engine oil and filter

Fuel filter

Fuel lines, fuel hoses and con-

nections

The engine oil and filter should be

A clogged filter can limit the speed at

changed at the intervals specified in

which the vehicle may be driven,

Check the fuel lines, fuel hoses and

the maintenance schedule. If the car

damage the emission system and

connections for leakage and dam-

is being driven in severe conditions,

cause multiple issues such as hard

age. We recommend that the fuel

more frequent oil and filter changes

starting. If an excessive amount of

lines, fuel hoses and connections be

are required.

foreign matter accumulates in the

replaced by an authoized HYUNDAI

fuel tank, the filter may require

dealer.

replacement more frequently.

Drive belts

After installing a new filter, run the

WARNING

Inspect all drive belts for evidence of

engine for several minutes, and

cuts, cracks, excessive wear or oil

Diesel only

check for leaks at the connections.

saturation and replace if necessary.

We recommend that the fuel filter be

Never work on injection system

Drive belts should be checked peri-

replaced by an authoized HYUNDAI

with engine running or within 30

odically for proper tension and

dealer.

seconds after shutting off

adjusted as necessary.

engine. High pressure pump,

rail, injectors and high pressure

NOTICE

pipes are subject to high pres-

sure even after the engine

When you are inspecting the belt,

stopped. The fuel jet produced

place the ignition switch in the

by fuel leaks may cause serious

LOCK/OFF or ACC position.

injury, if it touch the body.

People using pacemakers

should not move than

30cm

closer to the ECU or wiring har-

ness within the engine room

while engine is running, since

the high currents in the

Common Rail system produce

considerable magnetic fields.

7-23

Maintenance

Vapor hose and fuel filler cap

Vacuum crankcase ventilation

Air cleaner filter

hoses (if equipped)

The vapor hose and fuel filler cap

We recommend that the air cleaner

should be inspected at those inter-

Inspect the surface of hoses for evi-

filter be replaced by an authorized

vals specified in the maintenance

dence of heat and/or mechanical

HYUNDAI dealer.

schedule. Make sure that a new

damage. Hard and brittle rubber,

vapor hose or fuel filler cap is cor-

cracking, tears, cuts, abrasions, and

Spark plugs

rectly replaced.

excessive swelling indicate deterio-

ration. Particular attention should be

Make sure to install new spark plugs

paid to examine those hose surfaces

of the correct heat range.

nearest to high heat sources, such

as the exhaust manifold.

WARNING

Inspect the hose routing to assure

that the hoses do not come in con-

Do not disconnect and inspect

tact with any heat source, sharp

spark plugs when the engine is

edges or moving component which

hot. You may burn yourself.

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.

7-24

Cooling system

Automatic transaxle fluid

Brake hoses and lines

(if equipped)

Check cooling system components,

Visually check for proper installation,

such as radiator, coolant reservoir,

Automatic transaxle fluid should not

chafing, cracks, deterioration and

hoses and connections for leakage

be checked under normal usage

any leakage. Replace any deteriorat-

and damage. Replace any damaged

conditions.

ed or damaged parts immediately.

parts.

We recommend that the automatic

transaxle fluid changed by an author-

Brake fluid

ized HYUNDAI dealer according to

Coolant

the maintenance schedule.

Check brake fluid level in the brake

The coolant should be changed at

fluid reservoir. The level should be

the intervals specified in the mainte-

Information

between "MIN"

(Minimum) and

nance schedule.

"MAX" (Maximum) marks on the side

Automatic transaxle fluid color is

of the reservoir. Use only hydraulic

basically red.

brake fluid conforming to DOT 3 or

Manual transaxle fluid

As the vehicle is driven, the automatic

DOT 4 specification.

(if equipped)

transaxle fluid will begin to look darker.

Inspect the manual transaxle fluid

It is normal condition and you should

Parking brake

according to the maintenance sched-

not judge the need to replace the fluid

ule.

based upon the changed color.

Inspect the parking brake system

including the parking brake pedal

NOTICE

and cables.

The use of a non-specified fluid

could result in transaxle malfunc-

tion and failure.

Use only specified automatic

transaxle

fluid.

(Refer

"Recommended lubricants and

capacities" in chapter 8.)

7-25

Maintenance

Brake discs, pads, calipers

Drive shafts and boots

and rotors

Check the drive shafts, boots and

Check the pads for excessive wear,

clamps for cracks, deterioration, or

discs for run out and wear, and

damage. Replace any damaged

calipers for fluid leakage.

parts and, if necessary, repack the

grease.

Suspension mounting bolts

Air conditioning refrigerant

Check the suspension connections

(if equipped)

for looseness or damage. Retighten

to the specified torque.

Check the air conditioning lines and

Steering gear box, linkage &

connections for leakage and dam-

age.

boots/lower arm ball joint

With the vehicle stopped and engine

off, check for excessive free-play in

the steering wheel.

Check the linkage for bends or dam-

age. Check the dust boots and ball

joints for deterioration, cracks, or

damage. Replace any damaged

parts.

7-26

ENGINE OIL

Checking the engine oil level

3.Turn the engine off and wait for a

■ Gasoline engine

few minutes (about 5 minutes) for

■ Gasoline engine

the oil to return to the oil pan.

4.Pull the dipstick out, wipe it clean,

and reinsert it fully.

WARNING

Radiator hose

Be very careful not to touch the

OIB074006

■ Diesel Engine

radiator hose when checking or

OIB074004

adding the engine oil as it may

■ Diesel Engine

be hot enough to burn you.

5.Pull the dipstick out again and

check the level. The level should be

between F (Full) and L (Low).

NOTICE

OIB074005

• Do not spill engine oil, when

adding or changing engine oil. If

If it is near or at L (Low), add enough

OIB074003

you drop the engine oil on the

oil to bring the level to F

(Full).

1.Be sure the vehicle is on level

Do not overfill.

engine room, wipe it off immedi-

ground.

ately.

Use a funnel to help prevent oil

2.Start the engine and allow it to

from being spilled on engine com-

• When you wipe the oil level gauge,

reach normal operating tempera-

you should wipe it with a clean

ponents.

ture.

cloth. When mixed with debris, it

Use only the specified engine oil.

can cause engine damage.

(Refer to "Recommended lubricants

and capacities" in chapter 8.)

7-27

Maintenance

Changing the engine oil and

WARNING

filter

Used engine oil may cause skin

irritation or cancer if left in con-

tact with the skin for prolonged

periods of time. Used engine oil

contains chemicals that have

caused cancer in laboratory

animals. Always protect your

skin by washing your hands

thoroughly with soap and warm

water as soon as possible after

handling used oil.

We recommend that the engine oil

and filter be replaced by an author-

ized HYUNDAI dealer.

7-28

ENGINE COOLANT

The high-pressure cooling system

Checking the coolant level

(Continued)

has a reservoir filled with year-round

•

Turn the engine off and wait

antifreeze coolant. The reservoir is

WARNING

filled at the factory.

until it cools down. Use

extreme care when removing

Check the antifreeze protection and

Removing radiator

the radiator cap. Wrap a thick

coolant level at least once a year, at

cap

towel around it, and turn it

the beginning of the winter season,

counterclockwise slowly to

and before traveling to a colder cli-

the first stop. Step back while

mate.

the pressure is released from

•

Never attempt to remove the

the cooling system. When you

NOTICE

radiator cap while the engine

are sure all the pressure has

is operating or hot. Doing so

been released, press down on

• Do not drive with no engine

might lead to cooling system

the cap, using a thick towel,

coolant. It may cause water

and engine damage and could

and continue turning counter-

pump failure and engine seizure,

result in serious personal

clockwise to remove it.

etc.

injury from escaping hot

• Even if the engine is not oper-

• When the engine overheats from

coolant or steam.

ating, do not remove the radi-

low engine coolant, suddenly

(Continued)

ator cap or the drain plug

adding engine coolant may

while the engine and radiator

cause cracks in the engine. To

are hot. Hot coolant and

prevent damage, add engine

steam may still blow out

coolant slowly in small quanti-

under pressure, causing seri-

ties.

ous injury.

7-29

Maintenance

■ Gasoline engine

If the coolant level is low, add enough

WARNING

distilled

(deionized) water

(except

Middle East) or add enough pre-

The electric motor

mixed coolant

(for Middle East).

(cooling fan) is con-

Bring the level to F (Full), but do not

trolled by engine

overfill. If frequent additions are

coolant temperature,

required, we recommend that the

refrigerant pressure

system be inspected by an author-

and vehicle speed. It may some-

ized HYUNDAI dealer.

times operate even when the

engine is not running. Use

OIB074008

extreme caution when working

■ Diesel Engine

near the blades of the cooling

fan so that you are not injured

by a rotating fan blades. As the

engine coolant temperature

decreases, the electric motor

will automatically shut off. This

is a normal condition.

OIB074007

Check the condition and connections

of all cooling system hoses and

heater hoses. Replace any swollen

or deteriorated hoses.

The coolant level should be filled

between F

(Full) and L

(Low)

marked on the side of the coolant

reservoir when the engine is cool.

7-30

Recommended engine coolant

■ Gasoline engine

WARNING

•

Use only soft (distilled) water in the

coolant mixture.

Radiator cap

•

The engine in your vehicle has alu-

minum engine parts and must be

protected by an ethylene-glycol-

based coolant to prevent corrosion

and freezing.

Do not remove the radiator cap

•

DO NOT USE alcohol or methanol

when the engine and radiator are

coolant or mix them with the spec-

OIB074010

hot. Scalding hot coolant and

■ Diesel Engine

ified coolant.

steam may blow out under pres-

sure causing serious injury.

•

Do not use a solution that contains

more than 60% antifreeze or less

than 35% antifreeze, which would

reduce the effectiveness of the

solution.

For mixture percentage, refer to the

following table.

OIB074009

Mixture Percentage

Ambient

(volume)

Temperature

Antifreeze

Water

-15°C (5°F)

-25°C (-13°F)

-35°C (-31°F)

-45°C (-49°F)

7-31

Maintenance

Changing the coolant

WARNING

We recommend that the coolant be

replaced by an authorized HYUNDAI

Coolant

dealer.

• Do not use radiator coolant or

antifreeze in the washer fluid

NOTICE

reservoir.

Put a thick cloth or fabric around

• Radiator coolant can severely

the radiator cap before refilling

obscure visibility when sprayed

the coolant in order to prevent the

on the windshield and may

coolant from overflowing into

cause loss of vehicle control or

engine parts such as the alterna-

damage to paint and body trim.

tor.

7-32

BRAKE/CLUTCH FLUID (IF EQUIPPED)

Checking the brake/clutch

Before removing the reservoir cap

WARNING

fluid level

and adding brake/clutch fluid, clean

the area around the reservoir cap

■ Gasoline engine

Loss of brake fluid

thoroughly to prevent brake/clutch

fluid contamination. If the level is low,

In the event the brake system

add fluid to the MAX

(Maximum)

requires frequent additions of

level. The level will fall with accumu-

fluid, we recommend that the

lated mileage. This is a normal con-

system be inspected by an

dition associated with the wear of the

authorized HYUNDAI dealer.

brake linings and/or clutch disc

(if

equipped).

Information

If the fluid level is excessively low, we

recommend that the system be

Before removing the brake/clutch fil-

OIB074012

■ Diesel Engine

checked by an authorized HYUNDAI

ter cap, read the warning on the cap.

dealer.

WARNING

Use only the specified brake/clutch

fluid. (Refer to “Recommended lubri-

Clean filler cap before remov-

cants or capacities” in chapter 8.)

ing. Use only DOT3 or DOT4

Never mix different types of fluid.

brake/clutch fluid from a sealed

container.

OIB074011

Check the fluid level in the reservoir

periodically. The fluid level should be

between MAX (Maximum) and MIN

(Minimum) marks on the side of the

reservoir.

7-33

Maintenance

NOTICE

WARNING

Do not allow brake/clutch fluid to

Brake/clutch fluid

contact the vehicle's body paint,

When changing and adding

as paint damage will result.

brake/clutch fluid, handle it

Brake/clutch fluid, which has been

carefully. Do not let it come in

exposed to open air for an extend-

contact with your eyes. If

ed time should never be used as

brake/clutch fluid come in con-

its quality cannot be guaranteed. It

tact with your eyes, immediately

should be properly disposed.

flush them with a large quantity

Don't put in the wrong kind of

of fresh tap water. Have your

fluid. A few drops of mineral-

eyes examined by a doctor as

based oil, such as engine oil, in

soon as possible.

your brake/clutch system can dam-

age brake/clutch system parts.

7-34

AUTOMATIC TRANSAXLE FLUID (IF EQUIPPED)

Checking the automatic

2.After the transaxle is warmed up

transaxle fluid level

sufficiently

(fluid

temperature

70~80°C (158~176°F), for example

by 10 minutes usual driving, move

the shift lever through all the posi-

tions then place the shift lever in "N

(Neutral) or P (Park)" position.

OHD076045N

3.Confirm that the fluid level is in

"HOT" range on the level gauge. If

OIB074013

the fluid level is lower, add the

The automatic transaxle fluid level

specified fluid in the fill hole. If the

should be checked regularly.

fluid level is higher, drain the fluid

Keep the vehicle on the level ground

from the drain hole.

with the parking brake applied and

4.If the fluid level is checked in cold

check the fluid level according to the

condition

(fluid

temperature

following procedure.

20~30°C (68~86°F) add the fluid

1.Place the shift lever in N (Neutral)

to "C"

(COLD) line and then

position and confirm the engine is

recheck the fluid level according to

running at normal idle speed.

the above step 2.

7-35

Maintenance

NOTICE

Information

WARNING

• Low fluid level causes transaxle

A new automatic transaxle fluid

Transaxle fluid

slippage. Overfilling can cause

should be red. The red dye is added so

foaming, loss of fluid and

the assembly plant can identify it as

The transaxle fluid level should

transaxle malfunction.

automatic transaxle fluid and distin-

be checked when the engine is

• The use of a non-specified fluid

guish it from engine oil or antifreeze.

at normal operating tempera-

The red dye, which is not an indicator

ture. This means that the

could result in transaxle mal-

function and failure.

of fluid quality, is not permanent. As

engine, radiator, radiator hose

the vehicle is driven, the automatic

and exhaust system etc., are

transaxle fluid will begin to look dark-

very hot. Exercise great care

WARNING

er. The color may eventually appear

not to burn yourself during this

light brown. Therefore, we recom-

procedure.

Parking brake

mend that the system be replaced by

an authorized HYUNDAI dealer

To avoid sudden movement of

according

the

Scheduled

the vehicle, apply the parking

Maintenance at the beginning of this

brake and depress the brake

chapter.

pedal before moving the shift

lever.

Use only the specified automatic

transaxle fluid.

(Refer to "Recommended lubricants

Information

and capacities" in chapter 8.)

"C" (COLD) range is for reference

only and should NOT be used to deter-

Changing the automatic

mine the transaxle fluid level.

transaxle fluid

We recommend that the system be

replaced by an authorized HYUNDAI

dealer.

7-36

WASHER FLUID

PARKING BRAKE

Checking the washer fluid

Checking the parking brake

WARNING

level

Coolant

•

Do not use radiator coolant or

antifreeze in the washer fluid

reservoir.

•

Radiator coolant can severely

obscure visibility

when

sprayed on the windshield

and may cause loss of vehicle

control or damage to the paint

and body trim.

OIB054004

•

Windshield washer fluid

OIB074014

Check the stroke of the parking

agents contain some amounts

Check the fluid level in the washer

brake by counting the number of

of alcohol and can be flamma-

fluid reservoir and add fluid if neces-

“clicks’’ heard while fully applying it

ble under certain circum-

sary. Plain water may be used if

from the released position. Also, the

stances. Do not allow sparks

washer fluid is not available.

parking brake alone should securely

or flame come in contact with

hold the vehicle on a fairly steep

However, use washer solvent with

the washer fluid or the washer

grade. If the stroke is more or less

antifreeze characteristics in cold cli-

fluid reservoir. Damage to the

than specified, we recommend that

mates to prevent freezing.

vehicle or occupants could

the system be inspected by an

occur.

authorized HYUNDAI dealer.

•

Windshield washer fluid is

poisonous to humans and

animals. Do not drink and

Stroke : 6~8 “clicks’’ at a force of

avoid coming in contact with

20 kg (44 lbs, 196 N).

the windshield washer fluid.

Serious injury or death could

occur.

7-37

Hyundai i20 (2016 year). Instruction - part 21