2012 Hyundai VELOSTER (FS) G 1.6 GDI Service & Repair Manual

VELOSTER(FS) > 2012 > G 1.6 GDI > General Information 12345678910 - Identification Number Locations 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 – T : VELOSTER 3. Model ＆ Series – A : Low grade (L) – B : Middle-Low grade (GL) – C : Middle grade (GLS, JSL, TAX) – D : Middle-High grade (HGS) – E : 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 ○ ○ ○ × × ○ × × × × × J ○ ○ ○ ○ × ○ ○ × ○ ○ × L ○ ○ ○ ○ × ○ × × ○ ○ × 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 Hydraulic 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 – D : Gasoline engine 1.6 (Gamma 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 & Decelerator - G : LHD & DCT - L : RHD & MT - M : RHD & AT - N : RHD & MT+Transfer - S : RHD & AT+Transfer - T : RHD & CVT - U : RHD & Decelerator - V : RHD & DCT For U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen - Check digit : 0 ~ 9, × 8. Model year – B : 2011, C : 2012, D : 2013, E : 2014 ... 9. Plant of production – A : Asan (Korea) – B : Beijing (China) – C : Jeonju (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 MZH Phantom black PGU White crystal RHM Sleek silver N9S Sonic silver P9R Veloster red R9A Vitamin C SYY Sun flower T9U Clean blue UU9 Blue ocean VE9 Green apple 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) 4. Engine Capacity - D : 1591cc (Gamma GDI engine) 5. Production year - B : 2011, C : 2012, D : 2013, E : 2014 ... 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 (M6CF1) 1. Assembly code of plant 2. Production year - B : 2011, C : 2012, D : 2013, E : 2014 ... 3. Plant of production - U : Ulsan (Korea) - J : Ostrava (Czech) 4. Transaxle production sequence number - 000001 ~ 999999 Manual (D6GF1) 1. Assembly code - D13U : D6GF1

2. Production year - B : 2011, C : 2012, D : 2013, E : 2014 ... 3. Plant of production - W : Hyundai - WIA 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 Warning / Caution Label Locations

1. Fan caution 2. Radiator cap caution 3. Battery caution Battery Caution Label Description 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, excessive 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 regulations for battery disposal. Handling And Storage The Battery Battery Itself • Batteries should be stored in cool, dry (27˚/80.6℉) 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 ESC OFF indicator may illuminate. In this case, turn the handle 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 ESC OFF indicator may turn OFF. If the ESC OFF indicator does not turn OFF, have the system checked reffering to DTC. Lift And Support Points When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place additional weight in the luggage area before hoisting. When substantial weight is removed from the rear of the vehicle, the center of gravity may change and can cause the vehicle to tip forward on the hoist. • Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage area can assist with the weight distribution. • Use the same support points to support the vehicle on safety stands. 1. Place the lift blocks under the support points as shown in the illustration. 2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported. 3. Raise the hoist to full height to inspect the lift points for secure support.

Towing If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is very dangerous.

Emergency Towing There are three popular methods of towing a vehicle : – The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle. – The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. The other two wheels remain on the ground. – The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension, and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged if this method of towing is attempted. If the vehicle cannot be transported by flat-bed, should be towed with the wheels of the driving axle off the ground and do the following : Manual Transaxle • Release the parking brake. • Shift the Transaxle to neutral Automatic Transaxle • Release the parking brake. • Start the engine. • Shift to [D] position, then [N] position. • Turn off the engine. • The vehicle equipped with full-time 4WD should be only transported on a flat-bed. • The CVT vehicles should be only transported on a flat-bed or towed by wheel lift towing which the wheels of the driving axle are lifted off the ground. • Improper towing preparation will damage the transaxle. Follow the procedure above exactly. If you cannot shift the transaxle or start the engine(automatic transaxle), your vehicle must be transported on a flatbed. • It is the best to tow vehicle no farther than 30km (19miles), and keep the speed below 50km/h (30mph). (For the CVT and full-time 4WD (CVT/AT) vehicles, limit the towing distance and speed to 1.5km (1 mile) and 15km/h (10 mph).) • Trying to lift or tow your vehicle by the bumpers will cause serious damage to the vehicle. The bumpers are not designed to support the vehicle's weight. Tightening Torque Table Of Standard Parts BOLT (Nominal diameter) NUT (Nominal diameter) BOLT/NUT Normal screw Torque Nm (kg.m, Ib-ft) Nominal diameter. (mm) Pitch [mm (in.) ] 4T 8T 10T

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2012 Hyundai VELOSTER (FS) G 1.6 GDI Service & Repair Manual

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