General
GENERAL INFORMATION
ENGINE IDENTIFICATION NUMBER EXAMPLE :
GENERAL SERVICE INFORMATION
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas
before starting work.
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT
Be sure that all necessary tools and measuring
equipment are available starting work.
SPECIAL TOOLS
SDGGI9001L
Use special tools when they are required.
1) D : DIESEL ENGINE
G : GASOLINE ENGINE
C : CNG ENGINE
2) 4 : 4 CYCLE 4 CYLINDER
6 : 4 CYCLE 6 CYLINDER
8 : 4 CYCLE 8 CYLINDER
3) Engine development order
4) Engine version
5) Model year
9 : 2009 A : 2010 B : 2011 C : 2012 D : 2013
E : 2014 F : 2015 G : 2016 H : 2017 I : 2018
EAKE005A
6) Product serial number.
000001 ~ 999999
3. Cleaning parts for reuse
DISASSEMBLY
If the disassembly procedure is complex, requiring many
parts to be disassembled, all parts should be
disassembled in a way that will not affect their
performance or external appearance.
All parts to be used again should be carefully and
thoroughly cleaned by an appropriate method.
1. Inspection of parts
Each part, when removed, should be carefully
inspected for malfunction, deformation, damage, and
other problems.
EAKE005E
EAKE005C
PARTS
When replacing parts, use Hyundai genuine parts.
2. Arrangement of parts
All disassembled parts should be carefully arranged
for effective reassembly.
Be sure to separate and correctly identify the parts to
be replaced from those that will be used again.
ECBGI5011A
EAKE005D
REPLACEMENT
Standard values, such as torques and certain
adjustments, must be strictly observed in the reassembly
of all parts.
If removed, the following parts should always be replaced
with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
EAKE005H
ADJUSTMENT
Use gauges and testers to adjust correclty the parts to
standard values correctly.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the
negative (-) terminal of the battery.
2. Never pull
connectors.
on
the
wires
when
disconnecting
3. Locking connectors will click when the connector is
secure.
EAKE005G
4. Handle sensors and relays carefully. Be careful not to
drop them against other parts.
Depending on their location.
7. Sealant should be applied to gaskets.
8. Oil should be applied to the moving components of
parts.
9. Specified oil or grease should be applied to the
prescribed locations (oil seals, etc) before assembly.
EAKE005I
RUBER PARTS AND TUBES
Always prevent gasoline or from touching rubber parts or
tubing.
EAKE005K
MEASURING ACTUAL DIMENSIONS
EAKE005J
MEASURING BODY DIMENSIONS
1. Basically, all measurements in this manual are taken
with a tracking gauge.
2. When a measuring tape is used, check to be sure
there is no elongation, twisting or bending.
3. For
measuring
dimensions,
both
projected
dimensioners and actual - measurement dimensions
are used in this manual.
1. These dimensions indicate the actual linear distance
between mesaurement points, and are used as the
reference dimensions when a tracking gauge is used
for measurement.
2. First adjust both probes to the same length (A=A')
before measurement.
NOTICE
Check the probes and gauge itself to make sure
there is no free play.
DIMENSIONS PROJECTED
1. These are the dimensions measured when the
measurement points are projected from the vehicle's
surface, and are the reference dimensions used for
used for body alterations.
2. If the length of the tracking gauge probes is
adjustable, measure it by lengthening one of two
probes as long as the different value in height of the
two surface.
EAKE005L
MEASUREMENT POINT
Measurements should be taken at the center of the hole.
10.Check that the wiring has a little space so that it can
vibrate between fixed and moving parts such as the
vehicle body and the engine.
EAKE005M
CHECKING CABLES AND WIRES
1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery
electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks
and degrading.
EAKE005R
CHECK FUSES
A blade type fuse test taps are provided to allow
checking the fuse itself without removing if from the fuse
box. The fuse is good if the test lamp lights up when one
lead is connected to the test taps (one at a time) and the
other lead is grounded. (Turn the ignition switch on so
that the fuse circuit becomes operative)
5. Check the conductive parts of terminals for contact
with other metallic parts (vehicle body and other
parts).
6. Check grounded parts to verify that there is complete
continuity between thier attaching bolt(s) and the
vehicle's body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to prevent
contact with sharp corners of the vehicle body, etc. or
hot parts (exhaust manifold, etc.)
9. Check that the wiring is clamped firmy to provide
enough clearance from the fan pulley, fan belt and
other rotating or moving parts.
EAKE005O
SERVICING THE ELECTRICAL SYSTEM
1. Prior to servicing the electrical system, be sure to
turn off the ignition switch and disconnect the battery
ground cable.
EAKE005P
2. Attach the wiring harnesses with clamps so that there
is no slack. However, for any harness which passes
the engine or other vibrating parts of the vehicle,
allow some slack within a range that does not allow
the engine vibrations to cause the harness to come
into contact with any of the surronding parts and then
secure the harness by using a clamp.
3. If any section of a wiring harness interferes with the
edge of a parts, or a corner, wrap the section of the
harness with tape or something similar in order to
protect it from damage.
EAKE005S
4. When installing any parts, be careful not to pinch or
damage any of the wiring harness.
EAKE005T
EAKE005R
5. Never throw relays, sensors or electrical parts, or
expose them to strong shock.
EAKE005U
6. The electronic parts used in the computer, relays,
etc. are readily damaged by heat. If there is a need
for service operations that may cause the
temperature to exceed 80C (176F), remove the
electronic parts beforehand.
7. Loose connectors cause problems. Make sure that
the connectors are always securely fastened.
EAKE006B
8. When disconnecting a connector, be sure to grip only
the connector, not the wires.
EAKE006C
EAKE006A
9. Disconnect connectors which have catches by
pressing in the direction of the arrows shown in the
illustration.
11.When using a circuit tester to check continuity or
voltage on connector terminals, insert the test probe
into the harness side. If the connector is a sealed
connector, insert the test probe through the hole in
the rubber cap until the terminal contacts, being
careful not to damage the insulation of the wires.
EAKE006D
10.Connect connectors which have catches by inserting
the connectors until they make a clicking sound.
EAKE006G
12.To avoid overloading the wiring, take the electrical
current load of the optional equipment into
consideration, and determine the appropriate wire
size.
Permissible current
EAKE006E
Nominal
size
SAE gauge
No.
0.3mm
AWG 22
5A
0.5mm
AWG 20
7A
13A
0.85mm
AWG 18
9A
17A
1.25mm
AWG 16
12A
22A
2.0mm
AWG 14
16A
30A
3.0mm
AWG 12
21A
40A
5.0mm
AWG 10
31A
54A
In engine c Other areas
ompartment
Specification of Engine Oil
Type and quantity
Item
Specification
Engine oil
Above API CI-4 (SAE 10 W / 40)
Quantity
Oil pan
20.5
Oil pan + Oil filter
21
Oil pan + Oil filter + Oil cleaner(RRR oil filter)
23.5
TIGHTENING TORQUE TABLE OF STANDARD PARTS
Thin bolt
Bolt nominal diameter
(mm)
SDFGI8022D
Pitch(mm)
SDFGI8023D
Torque N.m(kgf.m , lb-ft)
Head mark 4
SDFGI8024D
Head mark 8
SDFGI8026D
M5
0.8
2~3
(0.2~0.3 , 1.5~2.2)
4.9~6.9
(0.5~0.7 , 3.6~5.1)
M6
3.9~5.9
(0.4~0.6 , 2.9~4.3)
7.8~11.8
(0.8~1.2 , 5.8~8.7)
M8
1.25
8.8~13.7
(0.9~1.4 , 6.5~10.1)
19.6~29.4
(2~3 , 14.5~21.7)
M10
1.25
18.6~27.4
(1.9~2.8 , 13.7~20.2)
44.1~58.8
(4.5~6 , 32.5~43.4)
M12
1.25
33.3~49
(3.4~5 , 24.6~36.2)
83.3~107.8
(8.5~11 , 61.5~79.5)
M14
1.5
58.8~83.3
(6~8.5 , 43.4~61.5)
127.4~176.4
(13~18 , 94~130.1)
M16
1.5
93.1~127.4
(9.5~13 , 68.69~94)
196~264.6
(20~27 , 144.6~195.2)
M18
1.5
137.2~186.2
(14~19 , 101.2~137.4)
294~392
(30~40 , 216.9~289.2)
M20
1.5
186.2~254.8
(19~26 , 137.4~188)
401.8~548.8
(41~56 , 296.4~404.9)
M22
1.5
254.8~343
(26~35 , 188~253.1)
548.8~735
(56~75 , 404.9~542.3)
M24
1.5
333.2~450.8
(34~46 , 245.8~332.6)
725.2~980
(74~100 , 535~723)
Thick bolt
Bolt nominal diameter
(mm)
Pitch(mm)
SDFGI8022D
SDFGI8023D
Torque N.m(kgf.m , lb-ft)
Head mark 4
SDFGI8024D
Head mark 8
SDFGI8026D
M5
1.5
17.6~26.5
(1.8~2.7 , 13~19.5)
42.1~58.8
(4.3~6 , 31.1~43.4)
M6
1.75
30.4~46.1
(3.1~4.7 , 22.4~34)
73.5~98
(7.5~10 , 54.2~72.3)
M8
53.9~73.5
(5.5~7.5 , 39.8~54.2)
117.6~166.6
(12~17 , 86.8~122.9)
M10
88.2~117.6
(9~12 , 65.1~86.8)
186.2~254.8
(19~26 , 137.4~188)
M12
2.5
117.6~156.8
(12~16 , 86.8~115.7)
254.8~343
(26~35 , 188~253)
M14
2.5
166.6~225.4
(17~23 , 122.9~166.3)
362.6~490
(37~50 , 267.5~361.5)
M16
2.5
225.4~303.8
(23~31 , 166.3~224.1)
490~666.4
(50~68 , 361.5~491.6)
M18
284.2~392
(29~40 , 209.7~289.2)
627.2~842.8
(64~86 , 462.7~621.8)
NOTICE
1. The torques shown in the table are standard values
under the following conditions :
Nuts and bolts are made of galvanized steel bar.
Galvanized plain steel washers are inserted.
All nuts, bolts and plain washers are dry.
2. The torques shown in the table are not applicable :
When spring washers, toothed washers and the
like are inserted.
If plastic parts are fastened.
If self-tapping screws or self-locking nuts are
used.
If threads and surfaces are coated with oil.
3. If you reduce the torques in the table to the
percentage indicated below, under the following
conditions, it will be the standard value.
If spring washers are used : 85%
If threads and bearing sufaces are stained with
oil : 85%
