2020 Hyundai VELOSTER (JS) G 1.6 T-GDI Service & Repair Manual

VELOSTER(JS) > 2020 > G 1.6 T-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 service and repair. There are various procedures, techniques, tools and pars for service as well as the skill of technicians. Therefore, it is impossible for this manual to provide advice or caution for each case. Accordingly, if you use a replacement part, service procedure, or tool which are not recommended by the vehicle manufacturer, make sure that neither the personal safety nor the safe operation of the vehicle is jeopardized. • 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 additional 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 the vehicle in the P position. • Place supporters against the front and rear surfaces of the tires to prepare for the vehicle suddenly 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 that the engine is not running.

VELOSTER(JS) > 2020 > G 1.6 T-GDI > General Information 12345678910 - Identification Number Identification Number Description Vehicle Identification Number 1. World Manufacturer Identifier (WMI)

- KMH : Passenger vehicle 2. Vehicle line - T : JS 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) - 6 : Premium GL grade (PGL) - 7 : Super HGSL grade (SHG) 4.Body / Cabin type, Gross Vehicle Weight Rating - 8 : Wagon 5. Restraint system, Brake system - 1 : Both side - Active Seat Belt 6. Engine type - A : NU 2.0 MPI - 5 : Gamma 1.6 T-GDI 7. Check digit or Driver’s side & Transmission - A : LHD & MT - B : LHD & AT - D : LHD & AT + Transfer - G : LHD & DCT - H : LHD & DCT + Transfer - L : RHD & MT - M : RHD & AT - S : RHD & AT + Transfer - V : RHD & DCT - W : RHD & DCT + Transfer 8. Model year – J : 2018, K : 2019, L : 2020, M : 2021 ... 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) – P : Piracicaba (Brazil) 10. Vehicle production sequence number – 000001 - 999999 Engine Number 1. Engine fuel - G : Gasoline - D : Diesel

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 - H : 1999cc (NU 2.0 AKS) - J : 1591cc (Gamma 1.6 T-GDI engine) 5. Production Year - J : 2018, K : 2019, L : 2020, M : 2021 ... 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 - M59U : D7UF1 2. Model year - J : 2018, K :2019, L : 2020, M : 2021 ... 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 (A6GF1-2) 1. Model - RA : A6GF 1-2 2. Model year - J : 2018, K : 2019, L : 2020, M : 2021 ... 3. Final gear ratio - U : 3.510 4. Detailed classification - A : NU 2.0 AKS 5. Plant of production - 2 : Powertech Plant2 - 4 : Powertech Plant4 - U : Ulsan Plant 1 - S : Ulsan Plant 2 - N : Ulsan Plant 3 - H : Hwasung 6. Transaxle production sequence number - 000001 - 999999 Manual (M6CF3-1) 1. Model - W : M6CF3-1 2. Model year - J : 2018, K : 2019, L : 2020, M : 2021 ... 3. Plant of production - U : Ulsan - H : Hwasung 4. Speed - 6 : 6-speed 5. Spare 6. Final gear ratio - A : 3.471 - B : 3.833 - C : 3.941 - D : 4.059 - E : 4.188 - F : 4.267 - G : 4.400 - H : 3.706 - J : 3.647 - K : 4.333

- L : 4.467 - M : 4.563 - N : 3.250 - P : 3.048 - R : 3.722 7. Transaxle production sequence number - 000001 - 999999 Paint Code One tone color Code Color W4G Gray MZH Phantom black S8K Saturn shadow MFR ignite flame_Red T5R shooting star_Aphotic dark gray S9T Ice storm_Aphotic gray P4U Cobalt eclipse _Blue U3U Aqua breeze P6W White choco TUY Thunderbolt SS7 Lake sillver YG7 Dark night TA9 Tangerine orange Two tone color Code Color MF1 Red + Black P41 Cobalt eclipse + Black P61 White choco + Phantom black SS1 Lake sillver + Phantom black S81 Saturn shadow + Black TT1 Tangerine orange + Phantom black TV1 Yellow + Black U31 Aqua breeze + Black W41 Space Gray + Black YG1 Dark night + Phantom black MF2 Red + Gray MZ2 Phantom black + Dark night P42 Cobalt eclipse + Dark night P62 White choco + Dark night SS2 Lake sillver + Dark night S82 Saturn shadow + Gray TT2 Tangerine orange + Dark night

TV2 Yellow + Gray U32 Aqua breeze + Gray W42 Space Gray + Gray

VELOSTER(JS) > 2020 > G 1.6 T-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 continued reliability, certain elements of the supplemental restraint system shall be serviced or replaced by an authorized dealer ten years after vehicle label.For further information. see owner's manual. Side Air Bag This vehicle is equipped with a side airbag system. To provide continued reliability, certain elements of the side airbag system shall be serviced or vehicle manufacturing date shown on the certification label. For further information, refer to the owner’s manual. 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 safety glasses for 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 could cause acid leakage, resulting in personal injury. Lift a battery 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 switch 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, rinse off 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, thoroughly wash the contacted area. If you feel a pain or a burning sensation, get medical attention immediately. E. Always read the following instructions carefully before handling a battery. F. Hydrogen, which is a highly combustible gas,is always contained 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. Battery Handling and Storage Battery • 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. Do not place any solution or objects (i.e. conductors) 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 installed in vehicle • When storing the vehicle for long periods of time, make sure to remove the battery fuse from the junction box to prevent natural discharging. • In case of the vehicle stored with the battery fuse connected, run the engine for battery charging within one month from the start of vehicle storage. In case of the vehicle stored with the battery fuse disconnected, run the engine for battery charging within three months from the start of vehicle storage. • After reconnecting or recharging a discharged battery, the ESP 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 ESP OFF indicator may turn OFF. • If the ESP OFF indicator does not turn OFF, have the system checked by referring to DTC. (Refer to the BR group.)

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2020 Hyundai VELOSTER (JS) G 1.6 T-GDI Service & Repair Manual

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