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Hyundai i800 (2016 year). Instruction - part 20

Maintenance

WARNING - Maintenance

CAUTION

WARNING - Diesel Engine

work

•

Do not put heavy objects or apply

Never work on injection system

•

Performing maintenance work on

excessive force on top of the

with engine running or within 30

a vehicle can be dangerous. You

engine cover (if equipped) or fuel

seconds after shutting off engine.

can be seriously injured whilst

related parts.

High-pressure pump, rail, injectors

performing some maintenance

•

When you inspect the fuel system

and high-pressure pipes are sub-

procedures. If you lack sufficient

(fuel lines and fuel injection

ject to high pressure even after the

knowledge and experience or the

devices), we recommend that you

engine stopped. The fuel jet pro-

proper tools and equipment to do

contact a HYUNDAI authorised

duced by fuel leaks may cause seri-

the work, we recommend that the

repairer.

ous injury, if it touches the body.

system be servied by a HYUNDAI

•

Do not drive long time with the

People using pacemakers should

authorised repairer.

engine cover (if equipped) removed.

not move than 30cm closer to the

•

Working under the bonnet with

•

When checking the engine room,

ECU or wiring harness within the

the engine running is dangerous.

do not go near fire.

engine room whilst engine is run-

It becomes even more dangerous

ning, since the high currents in the

Fuel, washer fluid, etc. are flam-

when you wear jewellery or loose

electronic engine control system

mable oils that may cause fire.

produce considerable magnetic

clothing. These can become

•

Before touching the battery, igni-

entangled in moving parts and

fields.

tion cables and electrical wiring,

result in injury. Therefore, if you

you should disconnect the bat-

must run the engine whilst work-

tery "-" terminal. You may get an

ing under the bonnet, make cer-

electric shock from the electric

tain that you remove all jewellery

current.

(especially rings, bracelets,

•

When you remove the interior

watches, and necklaces) and all

trim cover with a flat head (-) driv-

neckties, scarves, and similar

er, be careful not to damage the

loose clothing before getting

cover.

near the engine or cooling fans.

•

Be careful when you replace and

clean bulbs to avoid burns or

electrical shock.

7 5

Maintenance

OWNER MAINTENANCE

The following lists are vehicle checks and

Owner maintenance schedule

Whilst operating your vehicle:

inspections that should be performed at

•

Note any changes in the sound of the

When you stop for fuel:

the frequencies indicated to help ensure

exhaust or any smell of exhaust fumes

• Check the engine oil level.

safe, dependable operation of your vehi-

in the vehicle.

• Check coolant level in coolant reser-

cle.

•

Check for vibrations in the steering

voir.

If you have any question, we recommend

wheel. Notice any increased steering

• Check the windscreen washer fluid

that you consult a HYUNDAI authorised

effort or looseness in the steering

level.

repairer.

wheel, or change in its straight-ahead

• Look for low or under-inflated tyres.

These Owner Maintenance Checks are

position.

generally not covered by warranties and

•

Notice if your vehicle constantly turns

you may be charged for labour, parts and

slightly or “pulls” to one side when trav-

WARNING

lubricants used.

elling on smooth, level road.

Be careful when checking your

•

When stopping, listen and check for

engine coolant level when the

unusual sounds, pulling to one side,

engine is hot. Scalding hot coolant

increased brake pedal travel or “hard-

and steam may blow out under

to-push” brake pedal.

pressure. This could cause burns

•

If any slipping or changes in the oper-

or other serious injury.

ation of your transmission occurs,

check the transmission fluid level.

•

Check automatic transmission P (Park)

function.

•

Check parking brake.

•

Check for fluid leaks under your vehicle

(water dripping from the air condition-

ing system during or after use is nor-

mal).

7 6

Maintenance

EXPLANATION OF SCHEDULED MAINTENANCE ITEMS

Engine oil and filter

Fuel filter (cartridge)

Fuel lines, fuel hoses and con-

The engine oil and filter should be

A clogged filter can limit the speed at

nections

changed at the intervals specified in the

which the vehicle may be driven, damage

Check the fuel lines, fuel hoses and con-

maintenance schedule. If the car is being

the emission system and cause multiple

nections for leakage and damage.

driven in severe conditions, more fre-

issues such as hard starting. If an exces-

We recommend that the fuel lines, fuel

quent oil and filter changes are required.

sive amount of foreign matter accumu-

hoses and connectionsr be replaced by a

lates in the fuel tank, the filter may

HYUNDAI authorised repairer.

require replacement more frequently.

Drive belts

After installing a new filter, run the engine

Inspect all drive belts for evidence of

for several minutes, and check for leaks

WARNING - Diesel only

cuts, cracks, excessive wear or oil satu-

at the connections. We recommend that

Never work on injection system

ration and replace if necessary. Drive

the fuel filter be replaced by a HYUNDAI

with engine running or within 30

belts should be checked periodically for

authorised repairer.

seconds after shutting off engine.

proper tension and adjusted as neces-

High pressure pump, rail, injectors

sary.

and high pressure pipes are sub-

CAUTION

ject to high pressure even after the

In case the fuel filter is clogged due

CAUTION

engine stopped. The fuel jet pro-

to not conforming to the mainte-

When you are inspecting the belt,

duced by fuel leaks may cause seri-

nance period, the fuel injection

place the ignition switch in the

ous injury, if it touch the body.

equipment may supply the fuel

LOCK/OFF or ACC position.

People using pacemakers should

insufficiently, which may damage

not move than 30cm closer to the

the fuel injection equipment and

ECU or wiring harness within the

cause the engine to stall at worst

engine room whilst engine is run-

cases.

ning, since the high currents in the

Common Rail system produce con-

siderable magnetic fields.

7 9

Maintenance

Vapour hose and fuel filler cap

Air cleaner filter

Valve clearance (if equipped)

The vapour hose and fuel filler cap

We recommend that the air cleaner filter

Inspect for excessive valve noise and/or

should be inspected at those intervals

be replaced by a HYUNDAI authorised

engine vibration and adjust if necessary.

specified in the maintenance schedule.

repairer.

We recommend that the system be serv-

Make sure that a new vapour hose or fuel

iced by a HYUNDAI authorised repairer.

filler cap is correctly replaced.

Spark plugs (for petrol engine)

Make sure to install new spark plugs of

Cooling system

Vacuum crankcase ventilation

the correct heat range.

Check cooling system components, such

hoses (if equipped)

as radiator, coolant reservoir, hoses and

Inspect the surface of hoses for evidence

connections for leakage and damage.

WARNING

of heat and/or mechanical damage. Hard

Replace any damaged parts.

Do not disconnect and inspect

and brittle rubber, cracking, tears, cuts,

spark plugs when the engine is hot.

abrasions, and excessive swelling indi-

You may burn yourself.

Coolant

cate deterioration. Particular attention

The coolant should be changed at the

should be paid to examine those hose

intervals specified in the maintenance

surfaces nearest to high heat sources,

schedule.

such as the exhaust manifold.

Inspect the hose routing to assure that

the hoses do not come in contact with

any heat source, sharp edges or moving

component which might cause heat dam-

age or mechanical wear. Inspect all hose

connections, such as clamps and cou-

plings, to make sure they are secure, and

that no leaks are present. Hoses should

be replaced immediately if there is any

evidence of deterioration or damage.

7 10

Maintenance

Manual transmission fluid

Brake hoses and lines

Brake discs, pads, calipers and

(if equipped)

Visually check for proper installation,

rotors

Inspect the manual transmission fluid

chafing, cracks, deterioration and any

Check the pads for excessive wear, discs

according to the maintenance schedule.

leakage. Replace any deteriorated or

for run out and wear, and calipers for fluid

damaged parts immediately.

leakage.

Automatic transmission fluid

For more information on checking the

(if equipped)

Brake fluid

pads or lining wear limit, refer to the

HYUNDAI web site.

The fluid level should be in the "HOT"

Check brake fluid level in the brake fluid

(http://brakemanual.hmc.co.kr )

range of the dipstick, after the engine

reservoir. The level should be between

and transmission are at normal operating

“MIN” and “MAX” marks on the side of

temperature. Check the automatic trans-

the reservoir. Use only hydraulic brake

Suspension mounting bolts

mission fluid level with the engine run-

fluid conforming to DOT

3 or DOT 4

Check the suspension connections for

ning and the transmission in neutral, with

specification.

looseness or damage. Retighten to the

the parking brake properly applied.

specified torque.

Parking brake

✽ NOTICE

Inspect the parking brake system includ-

If your vehicle is not equipped with the

ing the parking brake lever and cables.

automatic transmission level gauge, we

recommend that the automatic trans-

mission fluid inspected by a HYUNDAI

authorised repairer according to the

maintenance schedule.

7 11

Maintenance

ENGINE OIL

5. Pull the dipstick out again and check

the level. The level should be between

F and L.

CAUTION

• Do not overfill with engine oil.

Engine damage may result.

• Do not spill engine oil, when

adding or changing engine oil. If

you drop the engine oil on the

engine room, wipe it off immedi-

ately.

OTQ077002L

OTQ077003L

• When you wipe the oil level

Checking the engine oil level

If it is near or at L, add enough oil to bring

gauge, you should wipe it with a

the level to F. Do not overfill.

1. Be sure the vehicle is on level ground.

clean cloth. When mixed with

2. Start the engine and allow it to reach

debris, it can cause engine dam-

normal operating temperature.

age.

Use a funnel to help prevent oil from

being spilled on engine components.

3. Turn the engine off and wait for a few

minutes (about 5 minutes) for the oil to

Use only the specified engine oil. (Refer

return to the oil pan.

CAUTION - Diesel engine

to “Recommended lubricants and capac-

4. Pull the dipstick out, wipe it clean, and

Overfilling the engine oil may cause

ities” in section 9.)

re-insert it fully.

severe dieseling due to churning

effect. It may lead to engine damage

accompanied with abrupt engine

WARNING - Radiator hose

speed increment, combustion noise

Be very careful not to touch the

and white smoke emission.

radiator hose when checking or

adding the engine oil as it may be

hot enough to burn you.

7 13

Maintenance

WARNING

Prolonged and repeated contact

with used engine oils may result in

serious skin disorders including

dermatitis and cancer. Avoid con-

tact with skin as far as possible and

always wash thoroughly after any

contact. Keep used oils out of

reach of children. It is illegal to pol-

lute drains, water courses and soil.

Use only authorised waste collec-

tion facilities including civic ameni-

ty sites and garages for the dispos-

Changing the engine oil and filter

al of used oil and oil filters. If in

We recommend that the engine oil and

doubt, contact the local authority

filter be replaced by a HYUNDAI autho-

for disposal instructions.

rised repairer.

7 14

Maintenance

ENGINE COOLANT

The high-pressure cooling system has a

Checking the coolant level

(Continued)

reservoir filled with year-round antifreeze

• Even if the engine is not operat-

coolant. The reservoir is filled at the fac-

WARNING

ing, do not remove the radiator

tory.

cap or the drain plug whilst the

Check the antifreeze protection and

Removing radiator

coolant level at least once a year, at the

engine and radiator are hot. Hot

cap

coolant and steam may still blow

beginning of the winter season, and

out under pressure, causing seri-

before travelling to a colder climate.

ous injury.

•

Never attempt to remove the radi-

CAUTION

ator cap whilst the engine is

•

Do not drive with no engine

operating or hot. Doing so might

coolant. It may cause water pump

lead to cooling system and

WARNING

failure and engine seizure, etc.

engine damage and could result

The electric motor (cool-

in serious personal injury from

ing fan) is controlled by

•

When the engine overheats from

escaping hot coolant or steam.

engine coolant tempera-

low engine coolant, suddenly

ture, refrigerant pres-

adding engine coolant may cause

•

Turn the engine off and wait until

sure and vehicle speed.

cracks in the engine. To prevent

it cools down. Use extreme care

when removing the radiator cap.

It may sometimes operate even

damage, add engine coolant

slowly in small quantities.

Wrap a thick towel around it, and

when the engine is not running.

Use extreme caution when working

turn it counterclockwise slowly to

near the blades of the cooling fan

the first stop. Step back whilst

so that you are not injured by a

the pressure is released from the

cooling system.

rotating fan blades. As the engine

coolant temperature decreases, the

When you are sure all the pres-

electric motor will automatically

sure has been released, press

shut off. This is a normal condition.

down on the cap, using a thick

towel, and continue turning coun-

terclockwise to remove it.

(Continued)

7 15

Maintenance

Recommended engine coolant

•

When adding coolant, use only deion-

ized water or soft water for your vehicle

and never mix hard water in the

coolant filled at the factory. An improp-

er coolant mixture can result in serious

malfunction or engine damage.

•

The engine in your vehicle has alu-

minium engine parts and must be pro-

tected by an ethylene-glycol-based

coolant to prevent corrosion and freez-

ing.

OTQ077004

•

DO NOT USE alcohol or methanol

OTQ072005

Check the condition and connections of

coolant or mix them with the specified

all cooling system hoses and heater

coolant.

WARNING

hoses. Replace any swollen or deterio-

•

Do not use a solution that contains

Radiator cap

rated hoses.

more than 60% antifreeze or less than

The coolant level should be filled

35% antifreeze, which would reduce

between F and L marks on the side of the

the effectiveness of the solution.

coolant reservoir when the engine is

cool.

For mixture percentage, refer to the fol-

Do not remove the radiator cap

If the coolant level is low, add enough

lowing table.

when the engine and radiator are

hot. Scalding hot coolant and

specified coolant to provide protection

Mixture Percentage

steam may blow out under pres-

against freezing and corrosion. Bring the

Ambient

(volume)

sure causing serious injury.

level to F, but do not overfill. If frequent

Temperature

additions are required, we recommend

Antifreeze

Water

that the system be inspected by a

-15°C (5°F)

35

65

HYUNDAI authorised repairer.

-25°C (-13°F)

40

60

-35°C (-31°F)

50

50

-45°C (-49°F)

60

40

7 16

Maintenance

Changing the coolant

We recommend that the coolant be

replaced by a HYUNDAI authorised

repairer.

CAUTION

Put a thick cloth or fabric around

the radiator cap before refilling the

coolant in order to prevent the

coolant from overflowing into

engine parts such as generator.

WARNING - Coolant

• Do not use radiator coolant or

antifreeze in the washer fluid

reservoir.

• Radiator coolant can severely

obscure visibility when sprayed

on the windscreen and may

cause loss of vehicle control or

damage to paint and body trim.

7 17

Maintenance

BRAKE AND CLUTCH (IF EQUIPPED) FLUID

Use only the specified brake fluid. (Refer

to “Recommended lubricants or capaci-

WARNING - Brake fluid

ties” in section 9.)

When changing and adding brake

fluid, handle it carefully. Do not let it

Never mix different types of fluid.

come in contact with your eyes. If

brake fluid should come in contact

with your eyes, immediately flush

WARNING - Loss of brake

them with a large quantity of fresh

fluid

tap water. Have your eyes examined

In the event the brake system

by a doctor as soon as possible.

requires frequent additions of fluid,

we recommend that the system be

OTQ077006R

inspected by a HYUNDAI autho-

CAUTION

rised repairer.

Checking the brake fluid level

Do not allow brake fluid to contact

Check the fluid level in the reservoir peri-

the vehicle's body paint, as paint

odically. The fluid level should be

damage will result. Brake fluid,

between MAX and MIN marks on the

✽ NOTICE

which has been exposed to open air

side of the reservoir.

Before removing the brake/clutch filter

for an extended time should never

cap, read the warning on the cap.

be used as its quality cannot be

Before removing the reservoir cap and

guaranteed. It should be disposed

adding brake fluid, clean the area around

of properly. Don't put in the wrong

the reservoir cap thoroughly to prevent

brake fluid contamination.

WARNING

kind of fluid. A few drops of miner-

al-based oil, such as engine oil, in

If the level is low, add fluid to the MAX

Clean filler cap before removing.

your brake system can damage

level. The level will fall with accumulated

Use only DOT3 or DOT4

brake system parts.

mileage. This is a normal condition asso-

brake/clutch fluid from a sealed

ciated with the wear of the brake linings.

container.

If the fluid level is excessively low, we

recommend that the system be checked

by a HYUNDAI authorised repairer.

7 18

Maintenance

POWER STEERING FLUID

✽ NOTICE

Use only the specified power steering

fluid. (Refer to "Recommended lubricants

Check that the fluid level is in the

or capacities" in section 9.)

"HOT" range on the reservoir. If the

fluid is cold, check that it is in the

"COLD" range.

Checking the power steering

hose

In the event the power steering system

Check the connections for oil leaks, dam-

requires frequent additions of fluid, we

age and twists in the power steering

recommend that the system be inspect-

hose before driving.

ed by a HYUNDAI authorised repairer.

CAUTION

OTQ077007

•

To avoid damage to the power

Checking the power steering fluid

steering pump, do not operate the

level

vehicle for prolonged periods

With the vehicle on level ground, check

with a low power steering fluid

the fluid level in the power steering reser-

level.

voir periodically. The fluid should be

•

Never start the engine when the

between MAX and MIN marks on the

reservoir tank is empty.

side of the reservoir at the normal tem-

•

When adding fluid, be careful that

perature.

dirt does not get into the reser-

Before adding power steering fluid, thor-

voir.

oughly clean the area around the reser-

•

Too little fluid can result in

voir cap to prevent power steering fluid

increased steering effort and/or

contamination.

noise from the power steering

If the level is low, add fluid to the MAX

system.

level.

•

The use of the non-specified fluid

could reduce the effectiveness of

the power steering system and

cause damage to it.

7 19

Maintenance

AUTOMATIC TRANSMISSION FLUID (IF EQUIPPED)

■ Type A

If your vehicle is equipped with the

automatic transmission level gauge,

inspect the fluid level as follows.

The automatic transmission fluid level

should be checked regularly.

Keep the vehicle on the level ground with

the parking brake applied and check the

fluid level according to the following pro-

cedure.

1. Place the selector lever in N (Neutral)

OTQ076008

position and confirm the engine is run-

■ Type B

ning at normal idle speed.

OTQ077009

2. After the transmission is warmed up

sufficiently (fluid temperature 70~80°C

3. Confirm that the fluid level is in “HOT”

(158~176°F), for example by 10 min-

range on the level gauge. If the fluid

utes usual driving, move the shift lever

level is lower, add the specified fluid

through all positions then place the

from the fill hole. If the fluid level is

selector lever in

“N

(Neutral) or P

higher, drain the fluid from the drain

(Park)” position.

hole.

4. If the fluid level is checked in cold con-

dition

(fluid temperature

20~30°C

(68~86°F) add the fluid to “C” (COLD)

OTQ073008

line and then recheck the fluid level

Checking the automatic transmis-

according to the above step 2.

sion fluid level

✽ NOTICE

If your vehicle is not equipped with the

automatic transmission level gauge, we

recommend that the automatic trans-

mission fluid inspected by a HYUNDAI

authorised repairer according to the

maintenance schedule.

7

20

Maintenance

✽ NOTICE

Changing the automatic transmis-

WARNING - Transmission

“C” (COLD) range is for reference only

sion fluid

fluid

and should NOT be used to determine

We recommend that the automatic trans-

The transmission fluid level should

transmission fluid level.

mission fluid changed by a HYUNDAI

be checked when the engine is at

authorised repairer according to the

normal operating temperature. This

✽ NOTICE

maintenance schedule.

means that the engine, radiator,

New automatic transmission fluid

radiator hose and exhaust system

should be red. The red dye is added so

etc., are very hot. Exercise great

the assembly plant can identify it as

care not to burn yourself during

automatic transmission fluid and distin-

this procedure.

guish it from engine oil or antifreeze.

The red dye, which is not an indicator of

fluid quality, is not permanent. As the

CAUTION

vehicle is driven, the automatic trans-

• Low fluid level causes transmis-

mission fluid will begin to look darker.

sion slippage. Overfilling can

The colour may eventually appear light

cause foaming, loss of fluid and

brown. Therefore, we recommend that

transmission malfunction.

the system be replaced by a HYUNDAI

authorised repairer according to the

• The use of a non-specified fluid

could result in transmission mal-

Scheduled Maintenance at the begin-

function and failure.

ning of this section.

Use only the specified automatic trans-

mission fluid. (Refer to “Recommended

WARNING - Parking brake

lubricants and capacities” in section 9.)

To avoid sudden movement of the

vehicle, apply parking brake and

depress the brake pedal before

moving the shift lever.

7 21

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