2018 HYUNDAI I20 fuel pump


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DDiesel engine
Diesel fuel
Diesel engine must be operated only
on commercially available diesel fuel
that complies with EN 590 or compa-
rable standard. (EN stands for
"European Norm"). Do not use
marine diesel fuel, heating oils, or
non-approved fuel additives, as this
will increase wear and cause dam-
age to the engine and fuel system.
The use of non-approved fuels and /
or fuel additives will result in a limita-
tion of your warranty rights.
Diesel fuel of above cetane 51 is
used in your vehicle. If two types of
diesel fuel are available, use summer
or winter fuel properly according to
the following temperature conditions.
• Above -5°C (23°F) ... Summer type
diesel fuel.
• 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.Do not let any petrol or water enter
the tank. This would make it neces-
sary to drain it out and to bleed the
lines to avoid jamming the injection
pump and damaging the engine.
- Diesel Fuel (if equipped with DPF)
It is recommended to use the regu-
lated automotive diesel fuel for diesel
vehicle equipped with the DPF sys-
tem.
If you use diesel fuel including high
sulfur (more than 50 ppm sulfur) and
unspecified additives, it can cause
the DPF system to be damaged and
white smoke can be emitted.
Biodiesel
Commercially supplied Diesel blends
of no more than 7% biodiesel, com-
monly known as "B7 Diesel" may be
used in your vehicle if Biodiesel
meets EN 14214 or equivalent spec-
ifications. (EN stands for "European
Norm"). The use of biofuels exceed-
ing 7% made from rapeseed methyl
ester (RME), fatty acid methyl ester
(FAME), vegetable oil methyl ester
(VME) etc. or mixing diesel exceed-
ing 7% with biodiesel will cause
increased wear or damage to the
engine and fuel system. Repair or
replacement of worn or damaged
components due to the use of non
approved fuels will not be covered by
the manufactures warranty.
• Never use any fuel, whether diesel, B7 biodiesel or otherwise,
that fails to meet the latest petrole-
um industry specification.
• Never use any fuel additives or treatments that are not recom-
mended or approved by the vehi-
cle manufacturer.
NOTICE
NOTICE
NOTICE

(12)
Luckno w (13) Sholapur (For the
v ehicles Manufactured on or after
\f1/\f6/2\f1\f).
(14) Puduchery \b (15) Mathur a\b (16)
vapi \b (17) Jamnagar \b (18)
Ankleshwar\b (19) Hissar\b (2\f)
Bharatpur\b (21) Silvasa\b (22) Daman
& Diu\b (23) Aligarh\b(24)RaeBareilly\b
(25) Unnao\b (26) Karnal\b (27)
Kurukshetra\b (28) Yamunanagar\b
(29 )Valsad\b (3\f) Nizamabad\b(31)
Medak & (3\f) Mehboobnagar (For
the vehicles Manufactured on or
after \f1/1\f/2\f1\f).
The Mass Emissipn Standards (BS
III) shall apply to all the states and
union territories\b except at above. As
and when Govt. of India notifies addi
tional/new cities under Mass
Emission Standards (BS IV)\b Such
cities would be auto matically cov
ered.
Subject to other terms of the warran
ty policy and the conditions and obli
gations laid down hereunder\b
Hyundai Motor India Limited here
inafter called “HMIL”\b certifies that
the components liable to affect the
emission of the gaseous pollutants in
the vehicle in normal use despite the
use to which it may be subjected\b
comply with the provisions of Rule 115(2) of the Central Motor Vehicle
Rules\b 1989 hereinafter referred to
as the “Inuse emission standard”\b
and further warrants that if on exam
ination by a dealer duly authorized
by HMIL\b the vehicle is discovered to
be failing to meet the Inuse emis
sion standard as specified in the said
rule\b our Authorized Dealer shall take
such corrective measures as may be
necessary and shall at its sole dis
cretion either repair or replace free of
charge\b such components of emis
sion control system as are specified
in paragraph 3 hereof.
1. Warranty period
This warranty will be in addition to
and run parallel to the New Vehicle
Warranty and shall exist for a period
of 36 months or until the vehicle has
been driven for a distance of 8\f\b\f\f\f
kilometers from the date of delivery
to the first purchaser\b whichever
occurs first. This warranty is transfer
able to subsequent owner for the
remaining warranty period.
2. What is covered Our Authorized Dealers shall either
repair or replace\b any Hyundai gen
uine part listed in paragraph 3 here
of\b that is acknowledged by HMIL to
be defective in material or workman
ship within the warranty period stipu
lated above\b after examinations car
ried out to confirm that none of the
original settings have been tampered
with\b at no cost to the owner of the
Hyundai vehicle for parts or labour.
Such defective par ts which have
been replaced will become the prop
erty of HMIL.
3. Emission Warranty Parts List
3.1 Engine Control Module System • Engine Control Module
• Crankshaft Position Sensor\bCamshaft Position Sensor\b
Throttle Position Sensor\b MAP
Sensor\b O 2Sensor\b IAT &
ECT Sensor
3.2 Fuel Metering System • Fuel injectors
• Fuel Pumps
3.3 Air Induction System • Air Cleaner Housing Assembly
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DDoor Ajar Warning LightThis warning light illumi-
nates:When a door is not close securely.Tailgate Open Warning
LightThis warning light illuminates:When the tailgate is not close
securely.
Fuel Filter Warning Light(Diesel Engine)This warning light illuminates:• When water has accumulated
inside the fuel filter.
In this case, remove the water from
the fuel filter.
For more details, refer to “Fuel
Filter” in chapter .
- Fuel Filter Warning Light
• When the Fuel Filter Warning Light illuminates, engine power (vehicle
speed & idle speed) may
decrease.
• If you keep driving with the warning light on, engine parts (injector,
common rail, high pressure fuel
pump) may be damaged. If this
occurs, we recommend that you
have the vehicle inspect ed by an
authorized HYUNDAI dealer as
soon as possible.
NOTICE
)'
#10*30-30.2+3%.,/3(21+2"1,/2*3!-$&3

1.$
,204/3424-3
Diesel Engine
Never work on injection system
with engine running or within 30
seconds after shutting of f engine.
High-pressure pump, rail, injectors
and high-pressure pipes are sub-
ject to high pressure eve n after
the engine stopped. The fuel jet
produced by fuel leaks may cause
serious injury, if it touches the
body. People using pacemakers
should not move more than 30cm
closer to the ECU or wiring har-
ness wi thin the engine room while
engine is running, since the high
currents in the electronic engine
control s ystem produce consider-
able magnetic fields.
WARNING
(Continued)
• When you remove the interior trim cover with a flat head (-) driver, be
careful not to dama ge the cover.
• Be careful when you replace and clean bulbs to avoid burns or elec-
trical shock.
Engine compartment precautions
(Diesel engine)• The injector operates at high volt-
age (maximum 200v). Therefore,
the following accidents may occur.
- Direct contact with the injector orinjector wiring may cause electric
shock or damage your muscle or
nerve system.
- The electromagnetic wave from the operating injector may cause
the artificial heart pacemaker to
malfunction.
• Follow the safety tips provided below, when you are checking the
engine room while the engine is
running.
- Do not touch the injector, injectorwirings, and the engine computer
while the engine is running.
- Do not remove the injector con- nector while the engine is run-
ning.
- People using pacemakers must not go near the engine while the
engine is starting or running.

1.%),204/3424-3$$ " !"##$$# !"$" "$#!$Engine oil and filterThe engine oil and filter should be
changed at the intervals specified in
the maintenance schedule. If the car
is being driven in severe conditions,
more frequent oil and filter changes
are required.Drive beltsInspect all drive belts for evidence of
cuts, cracks, excessive wear or oil
saturation and replace if necessary.
Drive belts should be checked peri-
odically for proper tension and
adjusted as necessary.When you are inspecting the belt,
place the ignition switch in the
LOCK/OFF or ACC position.
Fuel filterA clogged filter can limit the speed at
which the vehicle may be driven,
damage the emission system and
cause multiple issues such as hard
starting. If an excessive amount of
foreign matter accumulates in the
fuel tank, the filter may require
replacement more frequently.
After installing a new filter, run the
engine for several minutes, and
check for leaks at the connections.
We recommend that the fuel filter be
replaced by an authorized HYUNDAI
dealer.
Fuel lines, fuel hoses and con-
nectionsCheck the fuel lines, fuel hoses and
connections for leakage and dam-
age. We recommend that the fuel
lines, fuel hoses and connections be
replaced by an authorized HYUNDAI
dealer.
NOTICE
Diesel only
Never work on injection system
with engine running or within 30
seconds after shutting off engine.
High pressure pump, rail, injectors
and high pressure pipes are sub-
ject to high pressure even a fter
the engine stopped. The fuel jet
produced by fuel leaks may cause
serious injury, if it touch the b ody.
People using pacemakers should
not move than 30cm closer to the
ECU or wiring harness within the
eng ine room while engine is run-
ning, since the high currents in the
Common Rail system produce
considerab le magnetic fields.
WARNING

1.+',204/3424-3$#!$#
#!$$Draining water from fuel filterThe fuel filter for diesel engine plays
an important role of separating water
from fuel and accumulating the water
in its bottom.
If water accumulates in the fuel filter,
the warning light comes on when the
ignition switch is in the ON position.
If this warning light turned
on, we recommend that
the system be serviced by
an authorized HYUNDAI
dealer.If the water accumulated in the fuel
filter is not drained at proper times,
damages to the major parts such as
the fuel system can be caused by water permeation in the fuel filter.
Extracting air from the fuel filterIf you drive until you have no fuel left
or if you replace the fuel filter, be
sure to extract air from the fuel sys-
tem as it makes it difficult to start the
engine.
1. Pump up and down(1) approxi- mately 50 times until the pump is
hard.
2. Extract air from the fuel filter by removing the bolt(2) with a cross-
tip screw driver and reinstall the
bolt(2).
3. Pump up and down(1) approxi- mately 15 times.
4. Extract air from the fuel filter by removing the bolt(2) with a cross-
tip screw driver and reinstall the
bolt(2).
5. Pump up and down(1) approxi- mately 5 times.
Information
Use cloths when you extract air sothat the fuel is not sprayed around.
Clean the fuel around the fuel filter or the injection pump before start-
ing the engine to prevent fire.
Finally, check each part if the fuel is leaking.i
NOTICE
OIB074016

1.$%,204/3424-3[ ] : MFR (Multi Focus Reflector) Headlight
( ) : Bi-Function Projection HeadlightPCB Block (Gasoline engine)FF use Name
Symbol
Fuse rating
Circuit Protected
ECU 1
30A
PCB Block (Engine Control Relay, Fuse - F25)
HORN
15A
Horn Relay, B/Alarm Horn Relay
FUEL PUMP
20A
F/Pump Relay
WIPER FRT
25A
Wiper Lo Relay
DRL
(10A)
DRL Relay
H/LAMP LO
20A
H/Lamp Lo Relay
H/LAMP HI
[20A] (10A)
H/Lamp Hi Relay
C/FAN
40A
C/Fan Lo Relay, C/Fan Hi Relay
BLOWER
50A
Blower Relay
IG 2
30A
Start Relay, W/O Button Start : Ignition Switch, With Button St art : PDM Relay Box (IG2 Relay)
B+2
30A
I/P Junction Block (P/WDW Relay, TAIL Relay, Fuse - F1)
TCU 1
10A
1.2 CVT : PCM
ECU 3
15A
F/Pump Relay, ECM, C/Fan HI/LO Relay, Camshaft Position Sensor #1/#2, Oxygen Sensor
(Up/Down), Oil Control Valve #1/#2, Purge Control Solenoid Valve, Variable Intake Solenoid
Valve, A/CON Relay, Immobilizer Module
B/UP LAMP
B/UP
LAMP
10A
CVT : PCM, Transaxle Range Switch, Instrument Cluster, Audio
M/T : Back-Up Lamp Switch, I/P Junction Block (Fuse - F26)