light Hyundai Santa Fe 2004 Repair Manual

3WHAT TO DO IN AN EMERGENCY
9
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D060G02Y-AAT
6. Changing Wheels
D060H02O-AAT
7. Reinstall Wheel Nuts
Loosen the wheel nuts and remove them with
your fingers. Slide the wheel off the studs and
lay it flat so it cannot roll away. To put the wheel
on the hub, pick up the spare tire, line up the
holes with the studs and slide the wheel onto
them. If this is difficult, tip the wheel slightly and
get the top hole in the wheel lined up with the top
stud. Then jiggle the wheel back and forth until
the wheel can be slid over the other studs.WARNING:Wheels and wheel covers may have sharp
edges. Handle them carefully to avoid pos-
sible severe injury. Before putting the wheel
into place, be sure that there is nothing on
the hub or wheel (such as mud, tar, gravel,
etc.) that interferes with the wheel from
fitting solidly against the hub. If there is,
remove it. If there is not good contact on the
mounting surface between the wheel and
hub, the wheel nuts could come loose and
cause the loss of a wheel. Loss of a wheel
may result in loss of control of the vehicle.
This may cause serious injury or death.To reinstall the wheel, hold it on the studs, put
the wheel nuts on the studs and tighten them
finger tight. The nuts should be installed with
their small diameter ends directed inward. Jiggle
the tire to be sure it is completely seated, then
tighten the nuts as much as possible with your
fingers again.
HSM355HSM357
HSM356

4CORROSION PREVENTION AND APPEARANCE CARE
5CLEANING THE INTERIOR
E040B01A-AAT
To Clean the Leather Upholstery
(If installed)
In the normal course of use, leather upholstered
surfaces will, like any material, pick-up dust and
dirt. This dust and dirt must be cleaned off or it
may work into the surface of the leather, caus-
ing damage.
Fine leather needs care, and should be cleaned
when necessary. Washing leather thoroughly
with soap and water will keep your leather
lustrous, beautiful and ensure you have many
years of wear.
Take a piece of cheese cloth and using any mild
soap and lukewarm water, work up a good
lather. Thoroughly wash the leather. Wipe clean
with a slightly damp cloth and dry with soft cloth.
Do this as often as the leather becomes soiled.
During tanning operations, sufficient oils are
incorporated through processing that none need
be applied during the life of the leather. Oil
applied to the finished surface will in no way help
the leather and may do more harm than good.
Varnishes and furniture polishes should never
be used under any conditions.
E040A01A-AAT
To Clean the Vinyl Upholstery
To clean the vinyl upholstery, first remove loose
dirt and dust with a vacuum cleaner. Then apply
a solution of mild soap or detergent and water
using a clean sponge or soft cloth. Allow this to
stay on the surface to loosen the dirt, then wipe
with a clean damp sponge or cloth. If all the dirt
stains are not removed, repeat this procedure
until the upholstery is clean. Do not use gaso-
line, solvent, paint thinner or other strong clean-
ers.
E030E01A-AAT
Maintaining Bumpers
Special precautions must be observed to pre-
serve the appearance of the bumpers on your
Hyundai. They are:
o Be careful not to spill battery electrolyte or
hydraulic brake fluid on the bumpers. If you
do, wash it off immediately with clear water.
o Be gentle when cleaning the bumper sur-
faces. They are made of soft plastic and the
surface can be damaged if mistreated. Do
not use abrasive cleaners. Use warm water
and mild soap or car-washing solution.
o Do not expose the bumpers to high tem-
peratures. For example, if you have your car
repainted, do not leave the bumpers on the
car if the car is going to be placed in a high-
temperature paint booth.

6
Engine Compartment.............................................................. 6-2
General Checks....................................................................... 6-5
Checking the Engine Oil........................................................ 6-6
Changing the Oil and Filter.................................................... 6-7
Checking and Changing the Engine Coolant.................... 6-8
Spark Plugs...........................................................................6-10
Changing the Air Cleaner Filter.........................................6-12
Checking the Transaxle Oil (Manual) ..............................6-13
Checking the Transaxle Fluid (Automatic).....................6-14
Checking the Brakes...........................................................6-16
Checking the Clutch Fluid..................................................6-17
Air Conditioning Care ...........................................................6-18
Checking Drive Belts...........................................................6-20
Checking and Replacing Fuses ........................................6-21
Checking the Battery...........................................................6-22
Power Steering Fluid Level................................................6-24
Replacement of Light Bulbs...............................................6-26
Bulb Wattage .........................................................................6-33
Fuse Panel Description.......................................................6-34
6
DO-IT-YOURSELF MAINTENANCE

6DO-IT-YOURSELF MAINTENANCE
5GENERAL CHECKS
G020C01A-AAT
Vehicle Interior
The following should be checked each time
when the vehicle is driven:
o Lights operation
o Windshield wiper operation
o Horn operation
o Defroster, heating system operation (and air
conditioning, if installed)
o Steering operation and condition
o Mirror condition and operation
o Turn signal operation
o Accelerator pedal operation
o Brake operation, including parking brake
o Manual transaxle operation, including clutch
operation
o Automatic transaxle operation, including
"Park" mechanism operation
o Seat control condition and operation
o Seat belt condition and operation
o Sunvisor operation
If you notice anything that does not operate
correctly or appears to be functioning correctly,
inspect it carefully and seek assistance from
your Hyundai dealer if service is needed.
G020B01A-AAT
Vehicle Exterior
The following should be checked monthly:
o Overall appearance and condition
o Wheel condition and wheel nut torque
o Exhaust system condition
o Light condition and operation
o Windshield glass condition
o Wiper blade condition
o Paint condition and body corrosion
o Fluid leaks
o Door and hood lock condition
o Tire pressure and condition
(including spare tire)
G020A01A-AAT
Engine Compartment
The following should be checked regularly:
o Engine oil level and condition
o Transaxle fluid level and condition
o Brake fluid level
o Clutch fluid level
o Engine coolant level
o Windshield washer fluid level
o Accessory drive belt condition
o Engine coolant hose condition
o Fluid leaks (on or below components)
o Power steering fluid level
o Battery condition
o Air filter condition

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
21CHECKING AND REPLACING
FUSES
!
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
!
!
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
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
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