Hyundai Santa Fe 2004 Owner's Manual

6DO-IT-YOURSELF MAINTENANCE
17
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G120E02A-AAT
Adding Brake Fluid
WARNING:
Handle brake fluid carefully. It can damage
your vision if it gets into your eyes. Use only
DOT 3 or DOT 4 specification fluid from a
sealed container. Do not allow the fluid can
or reservoir to remain open any longer than
required. This will prevent entry of dirt and
moisture which can damage the brake sys-
tem and cause improper operation.
To add brake fluid, first wipe away any dirt then
unscrew the fluid reservoir cap. Slowly pour the
recommended fluid into the reservoir. Do not
overfill. Carefully replace the cap on the reser-
voir and tighten.
HSM158
CHECKING THE CLUTCH FLUID
G130A01A-AAT
To Check the Clutch Fluid
The clutch fluid level in the master cylinder
should be checked when performing other un-
der hood services. The system should be
checked for leakage at the same time. Check
to make certain that the clutch fluid level is
always between the "MAX" and "MIN" level
markings on the fluid reservoir. Fill as required.
Fluid loss indicates a leak in the clutch system
which should be inspected and repaired imme-
diately. Consult your Hyundai dealer.
HSM158
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G130B02A-AAT
To Replace the Fluid
Recommended brake fluid conforming to DOT
3 or DOT 4 specification should be used. The
reservoir cap must be fully tightened to avoid
contamination from foreign matter or moisture.
NOTE:Do not allow any other liquids to contami-
nate the brake fluid. Seal damage will result.
WARNING:Use caution when handling brake fluid. It
can damage your vision if you get it in your
eyes. It will also damage your vehicle's
paint if spilled on it and not removed imme-
diately.

6DO-IT-YOURSELF MAINTENANCE
18AIR CONDITIONING CARE
When the air conditioning is being used regu-
larly, the compressor drive belt tension should
be checked at least once a month with the
engine turned off.
To check the drive belt tension, press down on
the belt halfway between the engine crankshaft
and compressor pulleys. Pressing with your
finger, you should not be able to deflect this belt
anymore than 1/3 of an inch. If the belt is too
loose, have it adjusted by your Hyundai dealer.
G140D02A-AATChecking the Compressor Drive Belt
HSM396
2.7 V6 2.4 DOHC
COMP Auto tensioner
Eng.pulleyEng.pulleyCOMP
0.315 in.
G140D02L
3.5 V6
Crank shaft apulley
A/C pulley Power steering pulley
Generator
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G140A01A-AAT
Keeping the Condenser Clean
The air conditioning condenser (and engine
radiator) should be checked periodically for
accumulation of dirt, dead insects, leaves, etc.
These can interfere with maximum cooling ef-
ficiency. When removing such accumulations,
brush or hose them away carefully to avoid
bending the cooling fans.
G140C01A-AAT
Lubrication
To lubricate the compressor and the seals in the
system, the air conditioning should be run for at
least 10 minutes each week. This is particularly
important during cool weather when the air
conditioning system is not otherwise in use.
G140B01A-AATChecking the Air Conditioning Opera-
tion
1. Start the engine and let it run at a fast idle for
several minutes with the air conditioning set
at the maximum cold setting.
2. If the air coming out of the in-dash vents is
not cold, have the air conditioning system
inspected by your Hyundai dealer.
CAUTION:Running the air conditioning system for
extended periods of time with a low refrig-
erant level may damage the compressor.

6DO-IT-YOURSELF MAINTENANCE
19CHECKING THE FREE-PLAY
G160A01A-AAT
CLUTCH PEDAL
With the engine off, press lightly on the clutch
pedal until you feel a change in resistance. This
is the clutch pedal free-play. The free-play
should be within the limits specified in the illus-
tration. If it is not, have it inspected by your
Hyundai dealer and adjusted or repaired if
necessary.
G160A01E
0.24 ~ 0.51 in.
(6 ~ 13 mm)
G170A01A-AAT
BRAKE PEDAL
With the engine off, press down on the brake
pedal several times to reduce the vacuum in the
brake booster.
Then, using your hand, press down slowly on
the brake pedal until you feel a change in
resistance. This is the brake pedal free-play.
The free-play should be within the limits speci-
fied in the illustration above. If it is not, have it
inspected by your Hyundai dealer and adjusted
or repaired if necessary.
HXGS508
0.12 ~ 0.31 in.
(3 ~ 8 mm)
G150A01A-AAT
STEERING WHEEL
To check the steering wheel free-play, stop the
car with the wheels pointed straight ahead and
gently move the steering wheel back and forth.
Use very light finger pressure and be sensitive
to changes in resistance that mark the limits of
the free-play. If the free-play is greater than
specified, have it inspected by your Hyundai
dealer and adjusted or repaired if necessary.
G150A01O
1.18 in.
(30 mm)

6DO-IT-YOURSELF MAINTENANCE
20CHECKING BRAKE PEDAL
CLEARANCECHECKING DRIVE BELTS
G180A01A-AAT
You need a helper to check the brake pedal
clearance. With the engine running, have your
helper press down on the brake pedal several
times and then hold it down with a force of about
110 lbs (50 kg, 490 N). The brake pedal clear-
ance is the distance from the top surface of the
brake pedal to the asphalt sheeting under the
floor mat.
If the brake pedal clearance is not within the
limits specified in the illustration, have it in-
spected by your Hyundai dealer and adjusted
or repaired if necessary.
G180A01L
2.95 in. (75 mm)Drive belts should be checked periodically for
proper tension and adjusted if necessary. At the
same time, belts should be examined for cracks,
wear, fraying or other evidence of deterioration
and replaced if necessary.
Belt routing should also be checked to be sure
there is no interference between the belts and
other parts of the engine. After a belt is replaced,
the new belt should be adjusted again after two
or three weeks to eliminate slack resulting from
initial stretching after use.
G190A01A-AAT
HSM396
2.7 V6 2.4 DOHC
COMP
Eng.pulleyEng.pulleyCOMP
0.315 in.
Power steeringPower steering
Auto tensioner
GeneratorGeneratorEng.coolant
0.30~0.48 in.0.24~0.35 in.
G140D02L
3.5 V6
Crank shaft apulley
A/C pulley Power steering pulley
Generator

6DO-IT-YOURSELF MAINTENANCE
21CHECKING AND REPLACING
FUSES
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G200B01A-AATReplacing Accessory FusesCAUTION:
When replacing a fusible link, never use
anything but a new fusible link with the
same or lower amperage rating. Never use
a piece of wire or a higher-rated fusible link.
This could result in serious damage and
create a fire hazard.
The fuse box for the lights and other electrical
accessories will be found low on the dashboard
on the driver's side. Inside the box you will find
a list showing the circuits protected by each
fuse.
HSM391
If any of your car's lights or other electrical
accessories stop working, a blown (open) fuse
could be the reason. If the fuse has opened, you
will see that the metal strip inside the fuse has
melted through. If you suspect a blown fuse,
follow this procedure:
1 . Turn off the ignition and all other switches.
2 . Open the fuse box and examine each fuse.
Remove each fuse by pulling it toward you
(a small "fuse puller" tool is contained in the
fuse box to simplify this operation).
3 . Be sure to check all other fuses even if you
find one that appears to have opened.
HSM390
G200A02A-AAT
Replacing a Fusible Link
A fusible link will melt if the electrical circuits from
the battery are ever overloaded, thus prevent-
ing damage to the entire wiring harness. (This
could be caused by a short in the system
drawing too much current.) If this ever happens,
have a Hyundai dealer determine the cause,
repair the system and replace the fusible link.
The fusible links are located in a relay box for
easy inspection.
G200A01L
GoodOpen-
Replace

6DO-IT-YOURSELF MAINTENANCE
22CHECKING THE BATTERY
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4 . Replace the blown fuse by pressing a new
fuse of the same rating into place. The fuse
should be a snug fit. If it is not, have the fuse
clip repaired or replaced by a Hyundai dealer.
If you do not have a spare fuse, you may be
able to borrow a fuse of the same or lower
rating from an accessory you can tempo-
rarily get along without (the radio or cigarette
lighter, for example). Always remember to
replace the borrowed fuse.
CAUTION:An open fuse indicates that there is a prob-
lem in the electrical circuit. If you replace a
fuse and it blows as soon as the accessory
is turned on, the problem is serious and
should be referred to a Hyundai dealer for
diagnosis and repair. Never replace a fuse
with anything except a fuse with the same
or a lower amperage rating. A higher capac-
ity fuse could cause damage and create a
fire hazard.
G200B03Y
GoodOpen-Replace
!
G210A01A-AAT
WARNING:Batteries can be dangerous! When working
with batteries, carefully observe the follow-
ing precautions to avoid serious injuries.
The fluid in the battery contains a strong solution
of sulfuric acid, which is poisonous and highly
corrosive. Be careful not to spill it on yourself or
the car. If you do spill battery fluid on yourself,
immediately do the following:
D010B01YNOTE:See page 6-34 for the fuse panel descrip-
tions.

6DO-IT-YOURSELF MAINTENANCE
23CHECKING ELECTRIC COOLING
FANS
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G220A01A-AAT
WARNING:The cooling fan is controlled by engine
coolant temperature and may sometimes
operate even when the engine is not run-
ning. Use extreme caution when working
near the blades of the cooling fan, so that
you are not injured by a rotating fan blade.
As the engine coolant temperature de-
creases the fan will automatically shut off.
This is a normal condition.
G210B03A-AAT
Checking the Battery
Keep the battery clean. Any evidence of corro-
sion around the battery posts or terminals
should be removed using a solution of house-
hold baking soda and warm water. After the
battery terminals are dry, cover them with a light
coating of grease. o If battery fluid is on your skin, flush the
affected areas with water for at least 15
minutes and then seek medical assistance.
o If battery fluid is in your eyes, rinse out your
eyes with water and get medical assistance
as soon as possible. While you are being
driven to get medical assistance, continue to
rinse your eyes by using a sponge or soft
cloth saturated with water.
o If you swallow battery fluid, drink a large
quantity of water or milk followed by milk of
magnesia, eat a raw egg or drink vegetable
oil. Get medical assistance as soon as
possible.
While batteries are being charged (either by a
battery charger or by the vehicle's generator),
they produce explosive gases. Always ob-
serve these warnings to prevent injuries from
occurring:
o Charge batteries only in a well ventilated
area.
o Do not permit flames, sparks or smoking in
the area.
o Keep children away from the area.
PROPOSITION 65 WARNING:Battery posts, terminals, and related acces-
sories contain lead and lead compounds,
chemicals known to the State of California
to cause cancer and reproductive harm.
Batteries also contain other chemicals
known to the State of California to cause
cancer. Wash hands after handling.

6DO-IT-YOURSELF MAINTENANCE
24POWER STEERING FLUID LEVEL
G230A03A-AAT
G220C01A-AAT
Checking Condenser Cooling Fan
The condenser cooling fan should come on
automatically whenever the air conditioning is in
operation.
The power steering fluid level should be checked
regularly. To check the power steering fluid
level, be sure the engine is "OFF", then check
to make certain that the power steering fluid
level is between the "MAX" and "MIN" level
markings on the fluid reservoir.
NOTE:Grinding noise from the power steering
pump may be heard immediately after the
engine is started in extremely cold condi-
tions (below - 4°F). If the noise stops during
warm up, there is no abnormal function in
the system. It is due to a power steering
fluid characteristic in extremely cold condi-
tions.
G230A01O
G250A01A-AAT
FOR MORE INFORMATION ABOUT
YOUR HYUNDAI
If you desire additional information about main-
taining and servicing your Hyundai, you may
purchase a factory Shop Manual at your Hyundai
dealer's parts department. This is the same
manual used by dealership technicians and
while it is highly technical it can be useful in
obtaining a better understanding of your car and
how it works.
G240A01A-AAT
POWER STEERING HOSES
It is suggested that you check the power steer-
ing hose connections for fluid leakage at those
intervals specified in the vehicle maintenance
schedule in Section 5.
The power steering hoses should be replaced
if there is severe surface cracking, pulling,
scuffing or worn spots. Deterioration of the hose
could cause premature failure. Recommended Fluid
Use PSF-3 type fluid
NOTE:Do not start the engine when the power
steering oil reservoir is empty.
G220B01A-AAT
Checking Engine Cooling Fan
The engine cooling fan should come on auto-
matically if the engine coolant temperature is
high.

6DO-IT-YOURSELF MAINTENANCE
25HEADLIGHT AIMING ADJUSTMENT
G290B01O-AAT
Adjustment After Headlight Assembly
Replacement
If the vehicle has had front body repair and the
headlight assembly has been replaced, the
headlight aiming should be checked using an
aiming chart as shown in the illustration. Turn on
the headlight switch. (Low Beam Position)
1 . Adjust headlights so that main axis of light is
parallel to center line of the body and is
aligned with point "P" shown in the illustration.
2 . Dotted lines in the illustration show the center
of headlights.
G290A03O
L
W
H
H
Cut-off line
Ground line
"P"
Horizontal line
Vertical line
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6 . Draw the vertical line (through the center of
each headlight beam pattern) and the hori-
zontal line (through the center of each head-
light beam pattern) on the aiming screen.
And then, draw a parallel line at 0.8 in. (21
mm) under the horizontal line.
7. Adjust each cut-off line of the low beam to the
parallel line with a phillips screwdriver -
VERTICAL AIMING.
WARNING:Horizontal aiming should be adjusted by
an authorized Hyundai dealer.
G290A01O
Vertical
aiming
G290A02O-AAT
Before performing aiming adjustment, make
sure of the following.
1 . Keep all tires inflated to the correct pressure.
2 . Place the vehicle on level ground and press
the front bumper & rear bumper down sev-
eral times.
Place vehicle at a distance of 118 in. (3m)
from the test wall.
3 . See that the vehicle is unloaded (except for
full levels of coolant, engine oil and fuel, and
spare tire, jack, and tools). Have the driver
or equivalent weight placed in driver's seat.
4 . Clean the head light lenses and turn on the
headlights (Low beam).
5 . Open the hood.

6DO-IT-YOURSELF MAINTENANCE
26REPLACEMENT OF LIGHT BULBS
!
G260A02A-AAT
Before attempting to replace a light bulb, be sure
the switch is turned to the "OFF" position.
The next paragraph shows how to reach the
light bulbs so they may be changed. Be sure to
replace the burned-out bulb with one of the
same number and wattage rating.
See page 6-33 for the wattage description.
CAUTION:Keep the lamps out of contact with petro-
leum products, such as oil, gasoline, etc.
SPECIFICATION:
"H";
Horizontal center line of headlights from
ground: 2WD : 32.5 in.(822 mm)
4WD : 33.3 in.(843 mm)
"W";
Distance between each headlight center:
46.5 in.(1,178 mm)
"L";
Distance between the headlights and the
wall that the lights are tested against:
118 in. (3,000 mm).
G270A01O-AAT
Headlight and Front Turn Signal Light
1 . Allow the bulb to cool. Wear eye protection.
2 . Open the engine hood.
3. Always grasp the bulb by its plastic base,
avoid touching the glass.
4 . Using a socket wrench of the correct size,
remove the headlight assembly mounting
bolts.
HSM353