2005-2006 Hyundai Getz Service & Repair Manual

I nu I SUPPLEMENT FOREWORD This shop manual is intended for use by service technicians of authorized Hyundai dealers to help them provide efficient and correct service and maintenance on Hyundai vehicles. To ensure customer satisfaction with Hyundai products, proper service and maintenance by Hyundai technicians is essential. Consequently, it is important that service person- nel fully understand the contents of this manual, which should be kept in a handy place for quick and easy reference. All the contents of this manual, including photographs, drawings, and specifications, are the latest available at the time of printing. As modifications affecting service occur, dealers will be provided technical service bulletins or supple- mentary volumes. This manual should be kept carefully up- to date upon receipt of the new information. All information in the Workshop Manual is current at the time of publication. Hyundai Motor Company reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obliga- tions upon itself to install them on its products previously manufactured. JUN. 2005, Printed in Korea Regarding the information which is not provided in this manual, refer to '03 Getz Shop Manuai(Pub. No. : A 1CS-EG24A). CAUTION: I , Severe and transaxle may result from the use of poor fuels and lubricants that do 1 not meet You must ;:Jlii'!Jj,J;:Jl'IJ'~ fuels and lubricants that meet the c:nl::l!lf"i'tllf"!~-tor~n~ listed in the Recommended Lubricants L;ajpac:me::s Chart on Gl-7 in the General Information Section of the Manual. NOTE: For the circuit diagram of each group, refer to the "2006 Getz Electrical Troubleshooting Manual (Pub. No: A 1CE-EG56C)". CONTENTS TITLE General Information ENGINE (G4ED/G4EE- GSL1.6/1.4) ENGINE (D4FA- DSL1.5) Engine Electrical System (G4ED/G4EE- GSL1.6/1.4) Engine Electrical Sytem (D4FA- DSL 1.5) Emissions Control System (G4HD/G4EE/G4ED - GSL1.1/1.4/1.6) Fuel System (G4HD- GSL 1.1) Fuel System (G4ED/G4EE- GSL 1.6/1.4) Fuel System (D4FA- DSL 1.5) Clutch System Manual Transaxle (M5CF2) Restraints Body (Interior & Exterior) Body Electrical System Electrical Troubleshooting Manual GROUP Gl EM EMA EE EEA EC FL FLA FLB CH MT RT BD BE ETM All rights reserved. No part of this publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the prior written permission of Hyundai Motor Company.

Proper service methods and repair procedures are essential for safe, reliable operation of all motor vehicles as well as personal safety of the operator. The service procedures and descriptions in this shop manual provide general directions for a service and repair. Procedure, techniques, tools, and parts for service including the skill of the technician vary. It is impossible to provide advice or caution as to each case in this manual. Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is not recommended by the vehicle manufacturer, must first assure thoroughly that neither their personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement part, service procedure, or tool they select. WARNING : Remind you to be especially careful in those areas where carelessness can cause personal injury. & CAUTION : To prevent you from making errors that could damage the vehicle as well as personal injury. ~ NOTE : Gives you added information that will help you complete a particular procedure. The following list contains some general WARNINGS that you should follow while working on a vehicle. • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires you to be under the vehicle. 111 Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. • Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in park unless instructed otherwise for a specific operation • Place supporters against the front and rear surfaces of the tires to help prevent the vehicle from moving • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide poisoning. • Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts. • io prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. • Do not smoke while working on a vehicle. • To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. • When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even though the ignition switch is in the OFF position. For this reason care should be taken to ensure that the radiator fan electric motor is completely disconnected when working under the hood and the engine is not running.

I I • I IDENTIFICATION NUMBER ................ Gl - 2 BATTERY CAUTION LABEL TIGHTENING TORQUE TABLE OF DESCRIPTION ...................................... Gl - 11 STANDARD PARTS ............................ Gl- 6 LIFT AND SUPPORT POINT ............... Gl - 12 LUBRICANTS ....................................... Gl - 7 TOWING ................................................ Gl- 14 SELECTION OF ENGINE OIL ............. Gl - 8 GENERAL SERVICE INFORMATION .. Gl- 15

Gl-2 GENERAL IDENTIFICATION NUMBER LOCATIONS E62CB69D [5- DOOR] Vehicle lndentification Number. label paint code Passenger seat. Vehicle indentification Number. GENERAL INFORMATION [3- DOOR] EAPG050A

GENERAL IDENTIFICATION NUMBER DESCRIPTION VEHICLE IDENTIFICATION NUMBER K M H B U 5 2 8 P 5 U 000001 TTTTTTTTTTTT 1 2 3 4 56 7 8 91011 12 1. Geographic zone - K: Korea 2. Manufacturer - M : Hyundai motor company 3. Vehicle type - H : Passenger 4. Vehicle line - B: GETS 5. Model & Series - S : STANDAD (L) - T : DELUXE (GL) - U: SUPER DELUXE (GLS) 6. Body type - 3 : Sedan 3-door - 5 : Sedan 5-door 7. Restraint system - 0: None - 1 : Both side - Active belt - 2 : Both side - Passive belt - 3 : Driver side - Active belt & Air bag EAPG002A - 4 : Driver side & Passenger side - Active belt + Air bag Passenger side - Active belt or passive belt 8. Engine type - B: Gasoline 1.6 CVVT - G : Gasoline 1.1 SOHC - D : Gasoline 1.4 DOHC - V : Diesel 1.5 9. Check digit or others - P: LHD - R: RHO 10. Production year - 5 : 2005, 6 : 2006 11" Plant of production - U : Ulsan (korea) 12. Vehicle production sequence number - 000001 - 999999 PAINT CODE CODE COLOR NW Noble White EB Ebony Black HL Hiphop Red 3E Bule Onyx 5S Space Silver 9G Gold Beige 3W Sheer Yellow N8 Orange G8 Light Green 2B Sky Blue 2M Midnight Gray 8N Leaf Green Gl-3

[Gasoline] [Diesel] 1. 2. 3. G 4 E c 5 000001 TTTT TT 1 2 3 4 5 6 Engine fuel _ G : Gasoline _ o: Diesel Engine range _ 4 : 4 cycle 6 cylinder Engine develop_ment order _ E : Alpha eng1ne _ F : U-engine - H : Epsilon engine EAPG001B EAPG001C EAPG003A GENERAL INFORMATION 4. Engine capacity .I :) 1 599cc (Alpha) - 0: 1,085 cc (Epsl_on , , - E : 1,399 cc (Epsll~n) -A : 1,493cc (U-englne) 5 Production year . - 5 : 2005, 6 : 2006 . ence number Engine production sequ 6 . - 000001 - 999999 TRANSMISSION IDENTIFICATION NUMBER MANUAL ftTT 1 2 3 4 KAPF0010 KAPF001E KAPF004B

ERAL 1 : Model - P: M5CF2 - M: M5AF3 2 : Production year - 5 : 2005, 6 : 2006, 7 : 2007 3 : Gear ratio 1767: 3.941 2073: 3.650 4 : Transaxle production sequence number - 000001 - 999999 AUTOMATIC T 5 N XD D 000001 TTTT TT 1 2 3 4 5 6 1 : Modle - T: A4AF3 2 : Production year - 5 : 2005, 6 : 2006, 7 : 2007 3 : Gear ratio - N : 4.041 4 : Detailed chassification - XD: 1.4 DOHC - YD: 1.6 CWT 5: Spare 6 : Transaxle production sequence number - 000001 - 999999 Gl-5 KAPFOOSA KAPF001F

Gl-6 TIGHTENING TORQUE TABLE OF STANDARD PARTS Bolt niminal diameter Pich (mm) (mm) bPI•• i1fum AAIE006A AAIE007A M5 0.8 M6 1.0 GENERAL INFORMATION Torque Nm (kg.cm, lb.ft) Head Mark 4 Head Mark 7 @ )))))))) w )))))))) AAIEOOBA AAIE009A 3 - 4 (30 - 40, 2.2 - 2.9) 5 ... 6 (50 - 60, 3.6 - 4.3) 5 - 6 (50 - 50, 3.6 - 4.3) 9-11 (90- 110,6.5- 8.0) M8 1.25 12 - 15 (120 - 150, 9 - 11) 20 - 25 (200 - 250, 14.5 - 18.0 ) M10 1.25 25- 30 (250- 300, 18 ..... 22) 30- 50 (300- 500, 22- 36) M12 1.25 35 - 45 (350 - 450, 25 - 33) 60- 80 (600- 800, 43- 58) M14 1.5 75-85 (750 .... 850, 54- 61) 120 - 140 (1 ,200 - 1,400, 85 - 100) M16 1.5 110-130 (1,100 -1,300, 180- 210 (1,800- 2,100, 80 - 94) 130 - 150) M18 1.5 160- 180 (1,600- 1,800, 260 - 300 (2,600 - 3,000, 116 - 130) 190 - 215) M20 1.5 220- 250 (2,200- 2,500, 360 - 420 (3,600 - 4,200, 160 - 180) 260 - 300) M22 1.5 290- 330 (2,900- 3,300, 480 - 550 (4,800 - 5,500, 210 - 240) 350- 400) M24 1.5 360- 420 (3,600- 4,200, 610- 700 (6, 100 .... 7,000, [QJj) NOTE 1. The torques shown in the table are standard val- ues 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. 260- 300) 440- 505) 3. If you reduce the torques in the table to the per- centage indicated below, under the following conditions, if will be the standard value. • If spring washers are used : 85% • If threads and bearing sufaces are stained with oil : 85%

GENERAL Gl-7 LUBRICANTS RECOMMENDED LUBRICANTS Parts Specifications Engine oil API Classification SH OR Above - 1.1 (Gasoline) API Classification SJ/SL OR Above - 1.4/1.6 (Gasoline) API Classification CH OR Above - 1.5 (Diesel) Manual transaxle API Classification GL - 4 (SAE 75W/90 : Gasoline, SAE 75W/85W : Diesel) Automatic transaxle DIAMOND ATF SP - 3, SK ATF SP - 3 Brake DOT 3 or DOT 4 Cooling system High quality ethylene glycol - Concentration level 40% (tropical) - Concentration level 50% (tropical) Power steering PSF- 3 Transaxle linkage, parking brake cable mechanism, hood lock and hook, door Multipurpose grease NLGI grade #2 latch, seat adjuster, tailgate latch, door hinges, tailgate hinges WARNING Always use Genuine Hyundai parts and recomme- dended fluid. Using any other type of parts and fluid can cause serious damaged if the vehicle. LUBRICANTS CAPACITIES Description 1.1 (Gasoline) Oil pan 2.8 (2.96, 2.46) Engine oil Oil filter 0.2 (0.21' 0.18) Total 3.0 (3.17, 2.64) Cooling system 6.0 (6.34, 5.28) Manual transaxle 2.15 (2.27, 1.89) Automatic transaxle - Capacities 1.4/1.6(Gasoline) 3.0 (3.17, 2.64) 0.3 (0.32, 0.26) 3.3 (3.49, 2.90) 6.2 (6.55, 5.46) 2.15 (2.27, 1.89) 6.1 (6.45, 5.37) 1.5(Diesel) 4.0 (4.23, 3.52) 0.5 (0.53, 0.44) 5.3 (5.60, 4.66) 6.5 (6.87, 5.72) 2.0 (2.11, 1.76) - Power steering 0.9 (0.95, 0.79) 0.9 (0.95, 0.79) liter (U.S. qus., lmp.qts.)

Gl-8 SELECTION OF ENGINE OIL Recommended API classification : SH OR ABOVE - 1.1 (Gasoline) Recommended SAE viscosity grades : GENERAL INFORMATION Temperature range anticipated before next oil change Recommended SAE viscosity number ·c "F 40 104 20W 15W 10W 10W -50 -50 -50 -30 20 68 -40 -40 -40 10 50 5W -10 14 -40 *1 *1 5W -15 5 -30 sw· 1 -25 -13 -20. 2 *1 Restricted by driving condition and environment. *2 Not recommended for sustained high speed vehicle operation EDA9990B

2005-2006 Hyundai Getz Service & Repair Manual

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