check engine Hyundai Santa Fe 2004 Service Manual

6DO-IT-YOURSELF MAINTENANCE
15
!
G110D02O-AAT
To Check the Transaxle Fluid Level
Park the car on level ground with the parking
brake engaged. When the transaxle fluid level
is checked, the transaxle fluid should be at
normal operating temperature and the engine
idling.
While the engine is idling, apply the brakes and
move the gear selector lever from "P" to each
of its other positions — "R", "N", "D" — and then
return to "N" or "P". With the engine still idling:
1 . Open the hood, being careful to keep hands,
long hair and clothing clear of any moving
parts.
C090A01O G110C01O-AAT
Transaxle Fluid Capacity
The fluid capacity of the automatic transaxle is
8.98 U.S. quarts (8.5 liters).
WARNING:The transaxle fluid level should be checked
when the engine is at normal operating
temperature. This means that the engine,
radiator, exhaust system etc., are very hot
so you should exercise great care not to
burn yourself during this procedure.
G110B03A-AAT
Recommended Fluid
Your Hyundai automatic transaxle is specially
designed to operate with HYUNDAI GENUINE
ATF or DIAMOND ATF SP-III or SK ATF SP-III.
Damage caused by a nonspecified fluid is not
covered by your new vehicle limited warranty.
HSM425
2 . Remove the transaxle dipstick, wipe it clean,
reinsert the dipstick as far as it will go, then
remove it again. Now check the fluid level on
the dipstick. It should be in the "HOT" range
on the dipstick.
3 . If the transaxle fluid level is low, use a funnel
to add transaxle fluid through the dipstick
tube until the level reaches the "HOT" range.
Do not overfill.

6DO-IT-YOURSELF MAINTENANCE
16CHECKING THE BRAKES
G120D01A-AATTo Check the Fluid Level
The fluid level in the brake fluid reservoir should
be checked periodically. The level should be
between the "MIN" and "MAX" marks on the side
of the reservoir. If the level is at or below the
"MIN" mark, carefully add fluid to bring it up to
"MAX". Do not overfill.
!
G120C02A-AAT
Recommended Brake Fluid
Use only hydraulic brake fluid conforming to
DOT 3 or DOT 4 specifications in your braking
system. Follow the instructions printed on the
container.
G120B01A-AATChecking the Brake Fluid Level
WARNING:
Use caution when handling brake fluid. It
can damage your vision if it gets into your
eyes. It will also damage your vehicle's
paint if spilled on it and not removed imme-
diately.
!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.
HJM5044
Fluid level should be within "HOT" range
G120A01A-AAT
CAUTION:Because brakes are essential to the safe
operation of the car, it is suggested that
they be checked and inspected by your
Hyundai dealer. The brakes should be
checked and inspected for wear at those
intervals specified in the vehicle mainte-
nance schedule in Section 5.
!

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
!
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
23CHECKING ELECTRIC COOLING
FANS
!
!
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
!
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
34FUSE PANEL DESCRIPTION
G200C01O-AAT
Engine Compartment
G200C01O-ANOTE:Not all fuse panel descriptions in this manual may be applicable to your vehicle. It is accurate at the time of printing. When you inspect the
fuse box on your vehicle, refer to the fuse box label.FUSE
RATING
120A
50A
50A
40A
30A
30A
40A
30A
40A
20A
15A
10A
10A
20A
20A
10A
15A
20A
10A
10A
10APROTECTED COMPONENTS
Generator
Tail lamp relay, Fuse 11~17, Power connector
Start relay, Ignition switch
A/C Fuse, Blower relay
ABS control module, Air bleeding connector
ABS control module, Air bleeding connector
Engine contorl relay
Power window relay, Fuse 26
Radiator fan relay
Condenser fan relay
Fog lamp relay
Left head lamp, Instrument cluster, DRL control module
Right head lamp
Ignition failure sensor, Oxygen sensor
Injector
Check engine ind, ECM, PCM
Fuel pump relay, ECM, TCM, Generator, PCM
ATM contorl relay, 4WD control module
Horn relay
A/C relay
PCM, ECM
ALT
B+
IGN
BLR
ABS.1
ABS.2
ECU
P/W
RAD FAN
C/FAN
FRT FOG
H/LP(LH)
H/LP(RH)
ECU #1
ECU #2
ECU #3
ECU(B+)
ATM
HORN
A/C
ST SIG FUSIBLE
LINK
FUSE
DESCRIPTION

10INDEX
3
Corrosion protection
Cleaning the interior ....................................................................... 4-5
Protecting your Hyundai from corrosion ....................................... 4-2
Washing and waxing ...................................................................... 4-3
Cruise Control ...................................................................................1-75
D
Defrosting / Defogging ......................................................................1-87
Door
Central door lock ............................................................................ 1-7
Door locks ...................................................................................... 1-4
Front door edge warning light ......................................................1-74
Locking, unlocking front door with a key ...................................... 1-5
Drink Holder ......................................................................................1-55
Drive Belts .........................................................................................6-20
Driving
Driving for economy .....................................................................2-22
Smooth cornering.........................................................................2-23
Winter driving ...............................................................................2-23
E
Emission Control System................................................................... 7-2
Engine
Before starting the engine .............................................................. 2-3
Compartment (2.4 DOHC) ............................................................ 6-2
Compartment (2.7 V6) ................................................................... 6-3
Compartment (3.5 V6) ................................................................... 6-4
Coolant ........................................................................................... 6-8
Coolant temperature gauge .........................................................1-46If the engine overheats .................................................................. 3-4
Number........................................................................................... 8-2
Oil ................................................................................................... 6-6
Starting ........................................................................................... 2-5
Engine Exhaust Can Be Dangerous .................................................. 2-2
F
Fan Speed Control ............................................................................1-79
Floor Mat Anchor ..............................................................................1-73
Fog Light
Front.............................................................................................1-52
Front Seats
Adjustable front seats ..................................................................1-11
Adjustable headrests ...................................................................1-13
Adjusting seat forward and rearward ..........................................1-12
Adjusting seatback angle .............................................................1-12
Fuel
Auto fuel cut switch ......................................................................1-71
Capacity......................................................................................... 9-2
Gauge...........................................................................................1-46
Recommendations......................................................................... 1-2
Fuel Filler Lid
Remote release............................................................................1-71
Full-time 4WD Operation ..................................................................2-18
Fuses................................................................................................6-21
G
General Checks.................................................................................. 6-5
Glove Box ..........................................................................................1-60