2007 Hyundai H-1 (Grand Starex) fuel pump

1BEFORE DRIVING YOUR VEHICLE
2
B010A02CM-GAT Use Unleaded Gasoline For Europe
– For the optimal vehicle
performance, we recommend you to use unleaded gasoline with an octane rating of RON (Research Octane Num- ber) 95 /AKI (Anti Knock Index) 91 orhigher. You may use unleaded gasoline with an octane rating of RON 91~94/AKI 87~90but it may result in slight performance reduction of the vehicle. Except Europe – Unleaded gasoline
with a Pump Octane Rating of 87 (Re- search Octane Number 91) or highermust be used in Hyundai vehicle. If leaded gasoline is used, it will cause the catalytic converter to become inef- fective and the emission control sys- tem to malfunction.This can also result in increased main- tenance expense. To avoid accidental use of leaded fuel, the large nozzleused with leaded gasoline at service stations can not be inserted into fuel tank opening of Hyundai vehicle. NOTE:
o For some countries, Hyundai ve-
hicles are designed to use leaded gasoline. When you are going touse leaded gasoline, ask to Hyundai dealer whether leaded gasoline in your vehicle is avail-able or not.
o Octane rating of leaded gasoline
is same with unleaded one.
Use Diesel Diesel fuel Diesel engine must be operated only on commercially available diesel fuel thatcomplies with EN 590 or comparable standard. (EN stands for "European Norm"). Do not use marine diesel fuel,heating oils, or non-approved fuel addi- tives, as this will increase wear and cause damage to the engine and fuelsystem. The use of non-approved fuels and / or fuel additives will result in a limitation of your warranty rights.Diesel fuel of 52 to 54 cetane is used in Hyundai vehicle. If two types of diesel fuel are available, use summer or winterfuel properly according to the following temperature conditions. CAUTION:
Do not let any gasoline or water enterthe tank. This would make it neces- sary to drain it out and to bleed thelines to avoid jamming the injection pump and damaging the engine.
!
FUEL RECOMMENDATIONS
o Above -5°C (23°F) ... Summer typediesel fuel.
o Below -5°C (23°F) ... Winter type diesel fuel.
Watch the fuel level in the tank very carefully : If the engine stops through fuel failure, the circuits must be com-pletely purged to permit restarting.

44IN CASE OF EMERGENCY
22
2. Pump the hand pump until there are
no more bubbles in the fuel coming out of the air plug. When doing this,place a cloth around the air plug to prevent the escaping fuel from spew- ing about.
3. Tighten the air plug when there are no more bubbles in the fuel.
4. Continue pumping until the hand pump becomes stiff.
5. Finally, check to be sure that there
is no leakage of fuel.If in doubt, consult your nearest authorized HYUNDAI dealer. E090A02P
REMOVAL OF WATER FROM THE FUEL FILTER
E100A02P-GAT (Diesel Motor) If the fuel filter warning lamp illumi- nates during driving, it indicates that water has accumulated in the fuel fil-ter. If this occurs, remove the water as described below.
1. Loosen the drain plug at the bottom
of the fuel filter. Drain plug
!WARNING:
o Do not smoke or have any other open flame near the vehicle while bleeding the fuel system.
o Be sure to carefully clean away
any fuel which spilled ontonearby parts coming out of the air plug, because such accumu- lations of fuel might ignite andcause a fire.
GS40310A

4
CORROSION PREVENTION AND APPEARANCE CARE
23
4
IN CASE OF EMERGENCY
23IF THE ENGINE WILL NOT START
!WARNING:
o Do not smoke or have any other open flame near the vehicle while bleeding the fuel system.
o Be sure to carefully wipe away
any water drained out in thismanner, because the fuel mixed in the water might be ignited and result in a fire.
NOTE: It is recommended that water accu- mulated in the fuel filter should be removed by an authorized Hyundaidealer.
!
D010A01A-AAT
WARNING:
If the engine will not start, do not push or pull the car to start it. This could result in a collision or causeother damage. In addition, push or pull starting may cause the cata- lytic converter to be overloaded andcreate a fire hazard.
2. Operate the hand pump slowly 6 or 7 times in order to force the waterout through the drain plug.
3. Tighten the drain plug when water no longer comes out.
4. Loosen the air plug and bleed the air. (Refer to "Bleeding the fuel sys- tem".)
5. Check to be sure that the warning lamp illuminates when the ignitionkey is turned to "ON", and that itgoes off when the engine is started. If in doubt, consult your nearest authorized HYUNDAI dealer. Pump
GS40320A

44IN CASE OF EMERGENCY
26
4. Check to see if the water pump drivebelt is missing. If it is not missing, check to see that it is tight. If the drive belt seems to be satisfactory, check for engine coolant leakingfrom the radiator, hoses or under the car. (If the air conditioning had been in use, it is normal for coldwater to be draining from it when you stop).
!WARNING:
While the engine is running, keep hair, hands, long hair and clothing away from moving parts such as the fan and drive belts to preventinjury.
!WARNING (Diesel only):
Never work on injection system with engine running or within 30 sec- onds after shutting off engine. High pressure pump, rail, injectors andhigh pressure pipes are subject to high pressure even after the engine stopped. The fuel jet produced byfuel leaks may cause serious in- jury, if it touch the body. People using pacemakers should not movethan 30cm closer to the ECU or wiring harness within the engine room while engine is running, sincethe high currents in the Common Rail system produce considerable magnetic fields.
5. If the water pump drive belt is broken or engine coolant is leaking out, stop the engine immediately and call the nearest Hyundai dealer for assis- tance.!WARNING:
Do not remove the radiator cap when the engine is hot. This can allow coolant to be blown out of the open- ing and cause serious burns.
6. If you cannot find the cause of the overheating, wait until the engine temperature has returned to nor-mal. Then, if the engine coolant has been lost, carefully add coolant to the reservoir (page 8-12) to bringthe fluid level in the reservoir up to the halfway mark.
7. Proceed with caution, keeping alert for further signs of overheating. Ifoverheating happens again, call a Hyundai dealer for assistance.
CAUTION:
Serious loss of engine coolant indi-cates there is a leak in the coolingsystem and this should be checked as soon as possible by a Hyundai dealer.
!

44IN CASE OF EMERGENCY
40FUSE PANEL DESCRIPTION
G200B01P-GAT MINIBUS/VAN Engine Compartment (Diesel Engine)
G200A01P
NOTE: Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time of printing. When you inspect the fuse box on your vehicle, refer to the fuse box label. AMPE-
RAGES
120A80A 30A30A30A40A30A 40A30A 30A 40A 50A
15A/20A
10A30A10A 10A 10A15A 10A 10A15A CIRCUIT PROTECTED
Generator
Glow relay, Glow control module (D4BB) ABS control module
Blower relay
Rear blower relay Fuse 16, 25, 26
Condenser fan main relay, Condenser fan relay (LOW)
Ignition switch, Generator, Start relay, COMP. Fuse, I/C FAN Fuse, ECU Fuse. ABS control module
Power window relay, Siren relay
Tail lamp relay, Head lamp relay
Front fog lamp relay, Hor n relay, Power connector
Inter cooler fan relay, Air temperature switch/Windshield glass defogger
A/C compressor relay
Main power relay (D4CB), Engine control relay, Fuel pump relay(Gasoline)
Illuminations, Left rear combination lamp, Left license lamp
Illuminations, Right rear combination lamp, Right license lamp
Left/Right horn
Front fog lamp switch, Left /Right front fog lampLeft head lamp
Right head lamp, Instrument cluster
Hazard relay, Fuse 23, 24
ALT
GLOW ABS
FR HTR
RR HTR DEF.
C/FAN
IGN
ABS P/W
TAIL
BATT
I/C FAN/FR HTD COMP.
ECU
T/LP(LH) T/LP(LH) HORN
FOG
H/LP(LH)
H/LP(RH)
FUSIBLE
LINK
FUSE
DESCRIPTION
POWER CONNECTOR

4
CORROSION PREVENTION AND APPEARANCE CARE
41
4
IN CASE OF EMERGENCY
41
G200C01P-GAT (Gasoline Engine)
G200B01PAMPE-
RAGES
120A30A 30A30A40A30A 40A30A 30A 40A 50A
15A/20A
10A30A10A 10A 10A15A 10A 10A15A CIRCUIT PROTECTED
GeneratorABS control module
Blower relay
Rear blower relayFuse 16, 25, 26
Condenser fan main relay, Condenser fan relay (LOW)
Ignition switch, Generator, Start relay, COMP. Fuse,FR HTD Fuse,ECU Fuse. ABS control module
Power window relay, Siren relay
Tail lamp relay, Head lamp relay
Front fog lamp relay, Horn relay, Power connector
Inter cooler fan relay, Air temperature switch/Windshield glass defogger
A/C compressor relay
Main power relay (D4CB), Engine control relay, Fuel pump relay(Gasoline)
Illuminations, Left rear combination lamp, Left license lamp
Illuminations, Right rear combination lamp, Right license lamp
Left/Right horn
Front fog lamp switch, Left /Right front fog lamp Left head lamp
Right head lamp, Instrument cluster
Hazard relay, Fuse 23, 24
ALT
ABS
FR HTR
RR HTR
DEF.
C/FAN
IGN
ABS P/W
TAIL
BATT
I/C FAN/FR HTD
COMP.ECU
T/LP(LH) T/LP(LH) HORNFOG
H/LP(LH)
H/LP(RH)
FUSIBLE
LINK
FUSE
DESCRIPTION
POWER CONNECTOR

6VEHICLE MAINTENANCE REQUIREMENTS
4
KILOMETERS X 1000 MONTHS
NO.1 2 3 4 5 6 7 8 DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (GASOLINE)ENGINE OIL AND FILTER AIR CLEANER FILTER FUEL FILTER FUEL SYSTEM LEAKS SPARK PLUGS VACUUM CRANKCASE VENTILATION HOSE TIMING BELT DRIVE BELT (FOR WATER PUMP AND ALTERNATOR)
G010A03P-GAT EXCEPT EUROPEAN COMMUNITY The following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for all vehicle services to protect your warranty. Where both kilometers and time are shown, the frequency of service is determined by whichever occurs first. R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary80 64
I I I 90 72
R I
R I
7056
I I
60 48
R I I I I
50 40
I I
40 32
I I I
30
24
R I I
20 16
I I I
SCHEDULED MAINTENANCE
108
I I
5 4
See Note (1) See Note (2)
Unleaded LeadedSee Note (3) See Note (4)
Note: (1) For every 15, 000 KM or 12 months, whichever occurs first "R"
(2) For every 45,000 KM or 36 months, whichever occurs first "R"
(3) For every 100,000 KM : "R"
(4) For every 40,000 KM : "R"

6
VEHICLE MAINTENANCE REQUIREMENTS
5
NO. 1 2 3 4 5 6 7 8 9
1011 12 KILOMETERS X 1000 MONTHS
DESCRIPTION
ENGINE CONTROL SYSTEM MAINTENANCE (DIESEL) ENGINE OIL AND FILTER AIR CLEANER FILTER FUEL FILTER VALVE CLEARANCE INJECTION TIMING (IF EXHAUST GAS INCLUDES BLACK SMOKE) EGR SYSTEM (VALVE, TUBE, HOSE) TIMING BELT DRIVE BELT (FOR WATER PUMP AND ALTERNATOR) ENGINE IDLE SPEED FUEL SYSTEM LEAKS INJECTION NOZZLE (IF EXHAUST GAS INCLUDES BLACK SMOKE) VACUUM PUMP AND VACUUM HOSE
G020A06P-GAT R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
80 64
I
R II I I 90 72
R I I II I
7056
I I
60 48
R II I I I I I I
50 40
I I
40 32
I I I I I I
30 24
R I I II I
2016
I I I I I108
I I
5 4
I
See Note(1)
Note : (1) For every 5,000 KM or 6 months, whichever occurs first : "R" Republic of South Africa (If the vehicle is lubricated API CH-4 grade or above.) For every 7,500 KM or 6 months, whichever occurs first : "R"
(2) For every 45,000 KM or 36 months, whichever occurs first "R"
See Note(2)