General Information ............................. GI - 2

General Service Information ................ GI - 2

Specification.......................................... GI -10

GeneralInformation

GeneralGENERAL INFORMATIONENGINE IDENTIFICATION NUMBER EXAMPLE :

SDFGI9001L

1) D : DIESEL ENGINEG : GASOLINE ENGINEC : CNG ENGINE

2) 4 : 4 CYCLE 4 CYLINDER6 : 4 CYCLE 6 CYLINDER8 : 4 CYCLE 8 CYLINDER

3) Engine development order

4) Engine version

5) Model year9 : 2009 A : 2010 B : 2011 C : 2012 D : 2013E : 2014 F : 2015 G : 2016 H : 2017 I : 2018

6) Product serial number.000001 ~ 999999

GENERAL SERVICE INFORMATIONPROTECTION OF THE VEHICLEAlways be sure to cover fenders, seats, and floor areasbefore starting work.PREPARATION OF TOOLS AND MEASURINGEQUIPMENTBe sure that all necessary tools and measuringequipment are available starting work.SPECIAL TOOLSUse special tools when they are required.

EAKE005A

DISASSEMBLYIf the disassembly procedure is complex, requiring manyparts to be disassembled, all parts should bedisassembled in a way that will not affect theirperformance or external appearance.1. Inspection of parts

Each part, when removed, should be carefullyinspected for malfunction, deformation, damage, andother problems.

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2. Arrangement of partsAll disassembled parts should be carefully arrangedfor effective reassembly.Be sure to separate and correctly identify the parts tobe replaced from those that will be used again.

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3. Cleaning parts for reuseAll parts to be used again should be carefully andthoroughly cleaned by an appropriate method.

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PARTSWhen replacing parts, use Hyundai genuine parts.

ECBGI5011A

REPLACEMENTStandard values, such as torques and certainadjustments, must be strictly observed in the reassemblyof all parts.If removed, the following parts should always be replacedwith new ones.1. Oil seals2. Gaskets3. O-rings4. Lock washers5. Cotter pins (split pins)6. Plastic nuts

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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.

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ADJUSTMENTUse gauges and testers to adjust correclty the parts tostandard values correctly.ELECTRICAL SYSTEM1. Be sure to disconnect the battery cable from the

negative (-) terminal of the battery.2. Never pull on the wires when disconnecting

connectors.3. Locking connectors will click when the connector is

secure.4. Handle sensors and relays carefully. Be careful not to

drop them against other parts.

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RUBER PARTS AND TUBESAlways prevent gasoline or from touching rubber parts ortubing.

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MEASURING BODY DIMENSIONS1. 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 dimensionsare used in this manual.

DIMENSIONS PROJECTED1. These are the dimensions measured when the

measurement points are projected from the vehicle'ssurface, and are the reference dimensions used forused for body alterations.

2. If the length of the tracking gauge probes isadjustable, measure it by lengthening one of twoprobes as long as the different value in height of thetwo surface.

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MEASURING ACTUAL DIMENSIONS1. These dimensions indicate the actual linear distance

between mesaurement points, and are used as thereference dimensions when a tracking gauge is usedfor measurement.

2. First adjust both probes to the same length (A=A')before measurement.

NOTICECheck the probes and gauge itself to make surethere is no free play.

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MEASUREMENT POINTMeasurements should be taken at the center of the hole.

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PRECAUTIONS WHEN WELDINGWhen welding in the vehicle, be sure to disconnect twoECU connectors and the negative (-) and positive (+)terminals of battery. If two ECU connectors are notdisconnected when welding, the surge voltage of weldingcauses damage to ECU.Be sure to disconnect two ECU connectors since poorengine staring or abnormal operation may be caused. Inaddition, be sure to disconnect battery cable since thesurge voltage due to welding may cause damage tovarious sensors if welding is performed withoutdisconnecting battery cable.CHECKING CABLES AND WIRES1. 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.5. Check the conductive parts of terminals for contact

with other metallic parts (vehicle body and otherparts).

6. Check grounded parts to verify that there is completecontinuity between thier attaching bolt(s) and thevehicle'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 andother rotating or moving parts.

10.Check that the wiring has a little space so that it canvibrate between fixed and moving parts such as thevehicle body and the engine.

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CHECK FUSESA blade type fuse test taps are provided to allowchecking the fuse itself without removing if from the fusebox. The fuse is good if the test lamp lights up when onelead is connected to the test taps (one at a time) and theother lead is grounded. (Turn the ignition switch on sothat the fuse circuit becomes operative)

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SERVICING THE ELECTRICAL SYSTEM1. Prior to servicing the electrical system, be sure to

turn off the ignition switch and disconnect the batteryground cable.

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2. Attach the wiring harnesses with clamps so that thereis no slack. However, for any harness which passesthe engine or other vibrating parts of the vehicle,allow some slack within a range that does not allowthe engine vibrations to cause the harness to comeinto contact with any of the surronding parts and thensecure the harness by using a clamp.

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3. If any section of a wiring harness interferes with theedge of a parts, or a corner, wrap the section of theharness with tape or something similar in order toprotect it from damage.

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4. When installing any parts, be careful not to pinch ordamage any of the wiring harness.

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5. Never throw relays, sensors or electrical parts, orexpose them to strong shock.

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6. The electronic parts used in the computer, relays,etc. are readily damaged by heat. If there is a needfor service operations that may cause thetemperature to exceed 80°C (176°F), remove theelectronic parts beforehand.

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7. Loose connectors cause problems. Make sure thatthe connectors are always securely fastened.

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8. When disconnecting a connector, be sure to grip onlythe connector, not the wires.

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9. Disconnect connectors which have catches bypressing in the direction of the arrows shown in theillustration.

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10.Connect connectors which have catches by insertingthe connectors until they make a clicking sound.

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11.When using a circuit tester to check continuity orvoltage on connector terminals, insert the test probeinto the harness side. If the connector is a sealedconnector, insert the test probe through the hole inthe rubber cap until the terminal contacts, beingcareful not to damage the insulation of the wires.

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12.To avoid overloading the wiring, take the electricalcurrent load of the optional equipment intoconsideration, and determine the appropriate wiresize.

Nominalsize

SAE gaugeNo.

Permissible current

In engine co -mpartment Other areas

0.3mm² AWG 22 - 5A

0.5mm² AWG 20 7A 13A

0.85mm² AWG 18 9A 17A

1.25mm² AWG 16 12A 22A

2.0mm² AWG 14 16A 30A

3.0mm² AWG 12 21A 40A

5.0mm² AWG 10 31A 54A

Specification of Engine OilType and quantity

Item Specification

Engine oil Above API CI-4 (SAE 10 W / 40)

Quantity Oil pan 13.5 Liter

Total 14 Liter

ENGINE OIL GRADERecommended API grade : Cl-4 grade or higherRecommended SAE viscosity grade

SGZGI9005-1L

*1 is applied to restrictively according to area in use ordriving condition.

NOTICEThe following lubricants should be selected in allengines for best performance and maximumeffectiveness.1. The requirements for API classification should be

satisfied.

2. The proper SAE grade number should be given inambient temperature range.

3. Never use the lubricants which SAE grade numberand API classification in the container are notindicated.

TIGHTENING TORQUE TABLE OF STANDARD PARTSThin bolt

Bolt nominal diameter(mm) Pitch(mm)

Torque N.m(kgf.m , lb-ft)

Head mark 4 Head mark 8

SDFGI8022D SDFGI8023D SDFGI8024D 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 1 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)

Torque N.m(kgf.m , lb-ft)

Head mark 4 Head mark 8

SDFGI8022D SDFGI8023D SDFGI8024D 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 2 53.9~73.5(5.5~7.5 , 39.8~54.2)

117.6~166.6(12~17 , 86.8~122.9)

M10 2 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 3 284.2~392(29~40 , 209.7~289.2)

627.2~842.8(64~86 , 462.7~621.8)

NOTICE1. 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 thepercentage indicated below, under the followingconditions, it will be the standard value.• If spring washers are used : 85%• If threads and bearing sufaces are stained with

oil : 85%