2016 Hyundai TUCSON (TL) G 2.0 GDI Service & Repair Manual

TUCSON(TL) > 2016 > G 2.0 GDI > General Information - Important Safety Notice 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. • Reminds you to be especially careful in those areas where carelessness will cause death or serious injury. • Reminds you to be especially careful in those areas where carelessness may cause death or serious injury. • Reminds you to be especially careful in those areas where carelessness may cause personal injury. • Gives you information that will prevent you from making errors that could damage the vehicle. • 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. • 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. • To 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.

TUCSON(TL) > 2016 > G 2.0 GDI > General Information - Identification Number Identification Number Description Vehicle Identification Number 1. World Manufacturer Identifier (WMI) – KMF : Commercial vehicle (Van) –KMH : Passenger vehicle or MPV(Multipurpose Passenger Vehicle)/SUV(Sports Utility Vehicle)/RV(Recreational Vehicle) – KMJ : Van

– KM8 : MPV/SUV/RV (For U.S.A, Canada, Mexico only) 2. Vehicle line – J : TUCSON 3. Model ＆ Series – 1 : Low grade (L) – 2 : Middle-Low grade (GL) – 3 : Middle grade (GLS, JSL, TAX) – 4 : Middle-High grade (HGS) – 5 : High grade (TOP) 4.Body/Cabin type, Gross Vehicle Weight Rating KMF (Commercial vehicle / Van) Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China - X : Standard Cabin / Semi-Bonnet - Y : Double Cabin / Bonnet - Z : Super Cabin / Box For U.S.A, Canada, Mexico, Gulf Cooperation Council, China - 3 : Standard Cabin Class-E 4×2 / Semi-Bonnet Class-E 4×2 - 4 : Standard Cabin Class-E 4×4 / Semi-Bonnet Class-E 4×4 - 5 : Standard Cabin Class-F 4×2 / Semi-Bonnet Class-F 4×2 - 6 : Standard Cabin Class-F 4×4 / Semi-Bonnet Class-F 4×4 - 7 : Double Cabin Class-E 4×2 / Bonnet Class-E 4×2 - 8 : Double Cabin Class-E 4×4 / Bonnet Class-E 4×4 - 9 : Double Cabin Class-F 4×2 / Bonnet Class-F 4×2 - 0 : Double Cabin Class-F 4×4 / Bonnet Class-F 4×4 - A : Super Cabin Class-E 4×2 / Box Class-E 4×2 - B : Super Cabin Class-E 4×4 / Box Class-E 4×4 - C : Super Cabin Class-F 4×2 / Box Class-F 4×2 - D : Super Cabin Class-F 4×4 / Box Class-F 4×4 KMH - 1 : Limousine - 2 : Sedan - 2 door - 3 : Sedan - 3 door - 4 : Sedan - 4 door - 5 : Sedan - 5 door - 6 : Coupe - 7 : Convertible - 8 : Wagon - 9 : Commercial Van - 0 : Pick-Up KMJ - 1 : Box - 2 : Bonnet - 3 : Semi-Bonnet KM8 - 1 : Wagon 4×2 Class-A - 2 : Wagon 4×2 Class-B - 3 : Wagon 4×2 Class-C - 4 : Wagon 4×2 Class-D - 5 : Wagon 4×2 Class-E - 6 : Wagon 4×2 Class-F - 7 : Wagon 4×2 Class-G - A : Wagon 4×4 Class-A - B : Wagon 4×4 Class-B - C : Wagon 4×4 Class-C - D : Wagon 4×4 Class-D - E : Wagon 4×4 Class-E - F : Wagon 4×4 Class-F - G : Wagon 4×4 Class-G

5. Restraint system, Brake system KMH, KM8 Except U.S.A, Canada, Mexico - 0 : Both side - None - 1 : Both side - Active belt - 2 : Both side - Passive belt For U.S.A, Canada, Mexico Code Seat belt Front air bag Knee air bag Side air bag Curtain air bag Driver''s Passenger''s Driver''s Passenger''s 1st row 2nd row 3rd row 1st row 2nd row 3rd row A ○ ○ ○ × × ○ × × ○ ○ × B ○ ○ ○ × × × × × × × × C ○ ○ ○ × × ○ × × ○ ○ ○ D ○ ○ ○ × × ○ ○ × ○ ○ × E ○ ○ × × × × × × × × × F ○ ○ ○ × × ○ × × × × × N ○ × × × × × × × × × × KMJ Except U.S.A, Canada, Mexico - 7 : Hydraulic brake system - 8 : Pneumatic brake system - 9 : Mixed brake system For U.S.A, Canada, Mexico - X : Hydraulic brake system - Y : Pneumatic brake system - Z : Mixed brake system KMF Except U.S.A, Canada, Mexico - 7 : Hydraulic brake system - 8 : Pneumatic brake system - 9 : Mixed brake system For U.S.A, Canada, Mexico Code Restraint system Brake system Seat belt Front air bag Knee air bag Side air bag Curtain air bag Hydrauric Pneumatic Mixed Driver''s Passenger''s Driver''s Passenger''s 1st row 2nd row 3rd row 1st row 2nd row 3rd row X ○ × × × × × × × × × × ○ - - V ○ ○ × × × × × × × × × ○ - - W ○ ○ ○ × × × × × × × × ○ - - 6. Engine type – 2 : Gasoline engine 1.6 (GAMMA 1.6 T- GDI) – 4 : Gasoline engine 2.0 (NU 2.0 GDI) 7. Check digit or Driver’s side & Transmission Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen - A : LHD & MT - B : LHD & AT - C : LHD & MT+Transfer - D : LHD & AT+Transfer - E : LHD & CVT - F : LHD & Reducer

- G : LHD & DCT - H : LHD & DCT + Transfer - L : RHD & MT - M : RHD & AT - N : RHD & MT+Transfer - S : RHD & AT+Transfer - T : RHD & CVT - U : RHD & Reducer - V : RHD & DCT - W : RHD & DCT + Transfer For U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen - Check digit : 0 ~ 9, × 8. Model year – F : 2015, G : 2016, H : 2017, J : 2018... 9. Plant of production – A : Asan (Korea) – B : Beijing (China) – C : Cheonju (Korea) – H : Alabama (U.S.A) – M : Chennai (India) – U : Ulsan (Korea) – Z : Izmit (Turkey) – J : Ostrava (Czech) 10. Vehicle production sequence number – 000001 ~ 999999 Paint Code Code Color Z5G Pepper gray TCM Phantom black U5S Platinum silver R5U Ara blue PKW Pure white S5W Ruby wine NN5 Sepia topaz SA5 Sedona orange TY5 Milk tea VG5 Galaxy pearl Engine Number 1. Engine fuel - G : Gasoline 2. Engine range - 4 : 4 cycle 4 cylinder 3. Engine development order and capacity - F : GAMMA engine (Gasoline)

- N : NU engine (Gasoline) 4. Engine Capacity - J : 1591cc (Gamma T- GDI engine) - C : 1999cc (NU GDI engine) 5. Production Year - F : 2015, G : 2016, H : 2017, J : 2018... 6. Plant of production - A : Asan (Korea) - B : Beijing (China) - H : Hwasung (Korea) - K : Montgomery (U.S.A) - M : Chennai (India) - P : Poseung (Korea) - S : Sohari (Korea) - T : Izmit (Turkey) - U : Ulsan (Korea) - W : Shandong (China) - Z : Zilina (Slovakia) - 1 : Yancheng (China) 7. Engine production sequence number - 000001 ~ 999999 Transaxle Number Manual (D7UF1) 1. Assembly code - D17U : D7UF1 - D18U : D7UF1 (4WD) - D27U : D7UF1 (U-II) 2. Model year - F : 2015, G : 2016, H : 2017, J : 2018… 3. Plant of production - D : Hyundai - Dymos 4. Production month - 1 : January - 2 : February - 3 : March - 4 : April - 5 : May - 6 : June - 7 : July - 8 : August - 9 : September - A : Octorber - B : November - C : December 5. Transaxle production sequence number - 000001 ~ 999999 Automatic (A6MF1, A6MF1-1)

1. Model - EM : A6MF1 (NU 2.0 4WD) - EM : A6MF1 (NU 2.0 4WD) (NAS) - PA : A6MF1-1 (NU 2.0 2WD) 2. Model year - F : 2015, G : 2016, H : 2017, J : 2018… 3. Final gear ratio - V : 3.648 - T : 3.510 4. Detailed classification - J : NU 2.0 GDI (A6MF1 + 4WD) - K : NU 2.0 GDI (A6MF1 + 4WD) (NAS) - A : NU 2.0 GDI (A6MF1-1 + 2WD) (-NAS) - B : NU 2.0 GDI (A6MF1-1 + 2WD + ATF) (+NAS) 5. Plant of production - 2 : Powertech Plant2 - 4 : Powertech Plant - U : Ulsan Plant 1 - S : Ulsan Plant 2 - N : Ulsan Plant 3 - H : Hwasung 6. Transaxle production sequence number - 000001 ~ 999999

TUCSON(TL) > 2016 > G 2.0 GDI > General Information - Warning and Caution Labels 1. Radiator cap caution 2. Fan caution 3. Battery caution Attention SRS Vehicle This car is equipped with a supplemental restraint system. To provide continedreliablity, certain elements of the supplemental restraint system shallbe serviced or replaced by authorized dealer ten years after vehicle label.For further information. see owner''s manual. Side Air Bag This car is equipped with a side airbag system. To provide continued reliability,certain elements of the side airbag system shall be serviced or vehiclemanufacture date shown on certification label. For further information seeowner''s manual. Battery Caution Label Describtion

Warning / Caution Label (Cont''d) A. Keep lighted cigarettes and all other flames or sparks away from the battery. B. Wear eye protection when charging or working near a battery. Always provide ventilation when working in an enclosed space. • When lifting a plastic-cased battery, excesive pressure on acid to leak resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. • Never attempt to change the battery when the battery cables are connected. • The electrical ignition system works with high voltage. Never touch these components with the engine running or the ignition switched on. C. Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow battery acid to contact your skin, eyes, clothing or paint finish. D. If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate medical attention. If possible, continue to apply water with a sponge or cloth until medical attention is received. If electrolyte gets on your skin, throughly wash the contacted area. If you feel a pain or a burning sensation, get medical attention immediately. E. Always read the following instructions carefully when handing a battery. F. Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited. G. An improperly disposed battery can be harmful to the environment and human health.

Always confirm local regurations for battery disposal. Handling and Storage the Battery Battery Itself • Batteries should be stored in cool, dry (27 degrees Celsius) places and out of direct sunlight. • MF batteries are tightly sealed to prevent acid leakage. However, tilting the battery to an angle of 45 degrees can cause acid to leak through the vents on the sides. Therefore, batteries should always be stored in their upright positions. Prevent placing any aqueous or solid (i.e. conductors) bodies on top of the battery. • It is extremely dangerous to use tools, such as hammers, on the battery terminals when connecting cables to the mounted battery. Battery on Vehicle • When storing the vehicle for long periods of time, make sure to remove the memory fuse at junction box to prevent natural discharging. • Also, run the engine for battery charging within 1 month if the memory fuse wasn''t removed from the start of vehicle storing. If the memory fuse was removed, run the engine for battery charging within 3 months from the start of vehicle storing. • After reconnecting or recharging a discharged battery, the ESP OFF indicator may illuminate. • In this case, turn the steering wheel half way to the left and right whilst the ignition switch is in the ON position. • Then, restart the engine after the ignition is OFF. • The EPS OFF indicator may turn OFF. • If the EPS OFF indicator does not turn OFF, have the system checked refering to DTC. (Refer to the BR group.)

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2016 Hyundai TUCSON (TL) G 2.0 GDI Service & Repair Manual

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