The Hyundai Santa Fe Shop Manual is designed for authorized service technicians to ensure proper maintenance and service of Hyundai vehicles. It includes detailed sections on various systems, troubleshooting tables, and guidelines for using the manual effectively. The manual emphasizes the importance of using genuine Hyundai parts and provides safety precautions for vehicle servicing.
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Hyundai Santa Fe 00 06 - Compressed
The Hyundai Santa Fe Shop Manual is designed for authorized service technicians to ensure proper maintenance and service of Hyundai vehicles. It includes detailed sections on various systems, troubleshooting tables, and guidelines for using the manual effectively. The manual emphasizes the importance of using genuine Hyundai parts and provides safety precautions for vehicle servicing.
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
@ HYUNDAI
SANTA Fi
Shop Manual
FOREWORD
This shop manual is intended for use by service techni-
cians of authorized Hyundai dealers to help them provide
>
Bn
6. The electronic parts used in the computer, relays,
atc. damaged by heat. If there is
‘a need for service operations that may cause the
temperature to exceed 80°C (176°F ), remove the
electronic parts beforehand.
pee ir
(76'F)
7. Loose connectors cause problems. Make sure that
the connectors are always securely fastened.
eal GENERAL INFORMATION
Gl-9
‘8. When disconnecting a connector, be sure to grip
only the connector, not the wires.
9. Disconnect connectors which have catches by
Pressing in the direction of the arrows shown the
illustration.
EAT
10. Connect connectors which have catches by inserting
the connectors until they make a clicking sound,
~~
Boer
11. When, using a circuit tester, to check continuity or
voltage on connector terminais, insert the test probe
into the harness side. If the connector is a sealed
connector, insert the test probe through the hole in
the rubber cap until it contacts the terminal, being
careful not to damage the insulation of the wires.
O,
‘Test probe
Test probe Connector
12. To avoid overloading the wiring, take the electrical
current load of the optional equipment into consid-
eration, and determine the appropriate wire size.
Permissible current
SAE gauge tense Toor ar
ment eas
oa mm | awe 22 : 5A
oS mee | AWG20 7A 134
0.85 mm? | AWGIE oA 170
125mm? | AWGIG 124 228
20mm | ANGIE 16A 0A
[som [aware | 21a 0A
[emm [awe10 SIA En Gl -10
GENERAL INFORMATION
|.
PRECAUTIONS FOR CATALYTIC CONVERTER
CAUTION
Ita large amount of unburned gasoline flows into the
converter, it may overheat and create a fire hazard.
To prevent this, observe the following precautions
and explain them to your customer.
1. Use only unleaded gasoline.
2, Do not run the engine while the car is at rest for
‘a long time. Avoid running the engine at fast idle
speed for more than 10 minutes and at idle speed
for more than 20 minutes.
3. Avoid spark- jump tests. Do spark- jumps only
when absolutely necessary. Perform this test as
rapidly as possible and, while testing, never race
the engine,
4, Do not measure engine compression for an ex-
tended time. Engine compression tests must be
made as rapidly as possible,
5. Do not run the engine when the fuel tank is nearly
‘empty. This may cause the engine to misfire and
‘create an extra load on the converter.
6. Avoid coasting with the ignition turned off and during
prolonged braking.
7. Do not dispose of a used catalytic converter together
with parts contaminated with gasoline or oil.
SRS SYSTEM COMPONENTS INFORMATION
CUSTOMER CAUTIONS
Failure to cay out service operations in the correct
sequence could cause the airbag system to be deployed
unexpectedly during servicing, and a serious accident
to occur. Further, if there is a mistake in servicing
the airbag system, it is possible the airbag may fail
to operate when required. Before performing servic
(including removal or installation of parts, inspection
or replacement), be sure to read the following items
carefully, then fellow the correct procedures described
‘the repair manual.
1. Work must be started approx. 30 seconds or
longer after the ignition switch is turned to the
LOCK position and the negative (-) battery cable is
disconnected. (The aitbag system is equipped with
a back-up power source. if work is started within 30,
seconds after disconnecting the negative (-) terminal
Cable of the battery, the airbag may be operative.)
When the negative (-) terminal cable is disconnected
from the battery, the clock and audio systems
memories will be erased. Before starting work,
record the setting of the audio memory system.
When work is finished, reset the audio system as
before and adjust the clock.
2. Malfunction symptoms of the airbag system are
difficult to confirm, 80 diagnostic codes become
the most important source of information when
troubleshooting. When troubleshooting the airbag
system, always read the diagnostic codes before
disconnecting the battery,
3, Never use airbag parts from another vehicle. When
replacing parts, replace them with new parts.
4, Never attempt to disassemble and repalr the airbag
modules, SRSCM, clock spring and airbag wiring
hamess in order to reuse it.
5. If the SASCM or altbag module has been dropped,
or if there are cracks, dents or other defects in the
case, bracket or connector, replace them with new
ones.
6. After work on the airbag system is completed, re-set
the SRS SRI. GENERAL INFORMATION
Gi-tt
‘The jack provided with the Rigid rack (Satety stand) Garage jack (floor Jack)
vehicle (for reterence)
Single post litt Double post Itt Free wheel type of auto lift
{Hi bar litt)
asco
CAUTION Never support vehicle with only a jack. Always
1. Never use a jack beneath the lateral rod or rear
suspension assembly.
2. In order to prevent scratching the sub frame,
place a piece of cloth on the jack's contact
surface (to prevent corrosion caused by damage
to the coating).
use safety stands.
Do not attempt to raise one entire side of the
vehicle by placing a jack midway between the
front and rear wheels. To do so could result in
permanent damage to the body. GI-12
GENERAL INFORMATION
TIGHTENING TORQUE TABLE OF STANDARD PARTS
Bolt nominal diameter | Bit, (mm) Torque Nm (kg.cm, Ib.ft}
{mm) Head Mark 4 Head Mark 7
Pima [atin «= GOOD mp
vn | some — we
M5 0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3,6-4.3)
M6 1.0 5-6 (50-60, 3.6-4.3) 9-14 (90-110, 6.5-8.0)
M8 1.25 12-15 (120-150, 9-11) 20-25 (200-250, 14.5-18.0)
M10 1.25 25-30 (250-300, 18-22) 30-50 (300-500, 22-36)
M12 1,25 95-45 (350-450, 25-33) 60-80 (500-800, 43-58)
Mt4 15 75-85(750-850,54-61) 120-140(1,200-1,400,85-100)
MIE 15 110-130(1,100-1,300,80-94) 180-210(1,800-2,100, 130-150) |
M1, 15 160-180(1,600-1,800, 116-130) | 260-300(2,600-3,000, 190-215)
M20, 1.5 220-250 (2,200-2,500, ve | 360-420 (3,600-4,200,260-300)
M22, 15 290-330 (2,900-3,300, 210-240) | 490-550. (4,800-5,500,350-400)
M24 15 360-420 (3,600-4,200, 260-300) | 610-700 (6,100-7,000, 440-505)
NOTE
1
3. If you reduce the torques in the table to the
The torques shown in the table are standard
values under the following conditions:
+ Nuts and bolts are made of steel bar, and
galvanized.
+ Galvanized plain steel washers are inserted.
* All nuts, bolts, and plain washers are dry.
‘The torques shown in the table are not applica-
ble:
+ When Spring washers, toothed washers and
the like are inserted.
+ If plastic parts are fastened.
+ If self-tapping screws or self-locking nuts
are used.
+ I threads and surface are coated with oil.
percentage indicated below, under the following
conditions, if will be the standard value,
+ Ispring washers are used. : 85%
+ WW threads and bearing surfaces are stained
with oil. : 85% RECOMMENDED LUBRICANTS AND CAPACITIES GI -13
RECOMMENDED LUBRICANTS AND EAnc06
CAPACITIES
RECOMMENDED LUBRICANTS
Parts ‘Specifications Remarks
Engine oil API Classification S@ Above For further details, refer to SAE
viscosity number
Manual transaxle ‘API classification GL-4 ‘SAE grade number:
‘SAE 75W/90
‘Automatic transaxle GENUINE HYUNDAI transaxle oil,
GENUINE DIAMOND ATF SP-1IM
Brake ~ [pot 3 arbor
Cooling system High quality ethylene glycol Concentration level 50% (normal)
Concentration level 40% (tropical)
Power steering PSF-3
‘Transaxle linkage, parking brake ca-
bble mechanism, hood lock and hook,
door latch, seat adjuster, trunk latch,
door hinges, trunk hinges
Multipurpose grease NLGI grade #2
MWEAST : Middle East, GEN.: General
LUBRICANTS CAPACITIES
Areas
AUST: Australia,
EC : European Community
Capacities
Description
2.0 14/2414 2.7 V6
Engine oil fl pan 40 (4.21, 3.52) 42 (4.44, 3.69)
Ol finer 0.3 (0.92, 0.26) 10.3 (0.32, 0.26)
Total 4.3 (4.63, 3.78) | 4.5 (4.76, 3.95)
Cooling system 7.0 (7.35, 6.19) 7.0 (7.38, 6.19)
Manual transaxle 2.4 (2.20, 1.80) 2.4 (2.20, 1.80)
‘Aulomatic wansaxle 7.8 (6.2, 6.90) 35604752 |
Power steering 1.0 (1.08, 0.88) 1.0 (1.05, 0.88)
Mer (U.S. ats., Imp. gts.) MAINTENANCE INFORMATION
CHANGING ENGINE OIL exsono
1. Ifthe engine is cold, run the engine until it reaches
normal operating temperature.
2, Turn off the engine.
3. Remove the oll filer cap and drain plug. Drain the
engine oil.
4, Tighten the drain plug to the specified torque.
Tightening torque
Oil pan drain plug =
95-45 N.m (350-450 kg.cm, 25-33 Ib.)
NOTE
Whenever tightening the oil drain plug, use a new
drain plug gasket.
5. Fill new engine oil through the oil filer cap opening.
NOTE
Do not overfill, this will cause oil aeration and loss
of oil pressure.
6. Install the oil filler cap.
7. Start and run the engine.
8, Tumoff the engine and then check the oil level. Add
oil if necessary.
GENERAL INFORMATION
REPLACING THE ENGINE OIL FILTER
4. Use a fiter wrench to remove the oil filter.
2. Before installing a new oi fier on the engine, apply
clean engine oil to the surface of the rubber gasket.
3. Tighten the oil fiter to the specified torque.
Tightening torque
Oil filter : 12-16 N.m (120-160 kg.cm, 9-12 Ib.)
4, Start and run the engine and check for engine oil
leaks.
5. After turning off the engine, check the oil level and
add oil as necessary.
REPLACING THE AIR CLEANER FILTER
‘The air cleaner iter will become dirty during use and the
{itering efficiency will be substantially reduced. Replace
with @ new one as needed.
4. Disconnect the clip holding air cleaner filter cover.
2. Remove the air fier cover.
CAUTION
‘The air titer cover should be removed carefully
because intake hose includes the airflow sensor.
3. Remove the air cleaner filter. MAINTENANCE INFORMATION
GI-15
4, Install a new air cleaner filter and replace the air
cleaner filter cover.
CHECKING BELT TENSION
‘The belt tension is automatically adjusted by the auto-
tensioner.
ADJUSTING BELT TENSION
Refer to the EM and EMA-Sections.
COOLING SYSTEM
‘Check the cooling system for damaged hoses, loose or
leaking connections, or other possible causes of coolant
leaks.
ANTIFREEZE
The engine cooling system is provided with a mixture
of 50% ethylene glycol antifreeze and 50% water (For
the vehicles of tropical area, the engine cooling system
is provided with a mixture of 40% ethylene glycol anti-
freeze and 60% water at the time of manufacture.)
Since the cylinder head and water pump body are made
of aluminum alloy casting, be sure to use a 30 to 60%
ethylene glycol antifreeze coolant to assure corrosion
protection and freezing prevention.
CAUTION
M the concentration of the antifreeze is below 30%,
the anticorrosion property will be adversely affected.
In addition, if the concentration is above 60%, both
the antifreeze and engine cooling properties will
decrease, adversely affecting the engine. For these
reasons, be sure to maintain the concentration level
within the specified range.
TINH
MEASURING OF ANTIFREEZE
CONCENTRATION
Run the engine until the coolant is fully mixed. Drain
‘some coolant (antifreeze), and then measure the tem-
perature and specific gravity of the coolant. Determine:
its concentration and safe working temperature, If the
coolant is short of antifreeze, add antifreeze to a con-
centration of 50%. (Tropical Areas : 40%)
eam
REPLACING OF THE COOLANT
1. Set the temperature control lever to the hot position.
2. Remove the radiator cap.
CAUTION
Remove the cap slowly. The system is pressurized
and the coolant may be hot. Do not open the cap
‘when the engine is hot.
3. Loosen the drain plug to drain the coolant.
4, Drain the coolant from the reserve tank. GI -16
GENERAL INFORMATION
5. After draining the coolant, tighten the drain plug
securely.
6. Fill the radiator with the coolant up to its filer neck.
7. Fill the reserve tank with the coolant.
8 Warm up the engine unti! the thermostat opens,
remove the radiator cap and check the coolant level.
9. When the radiator is filed up to its filer neck, install
the radiator cap securely.
10. Fill the reserve tank with coolant up to the "FULL"
line.
REPLACING IGNITION CABLES
The ignition cables should be replaced periodically with
new ones. After replacing, make sure that the ignition
ables and terminals are properly connected and posi-
tioned correctly.
NOTE
When disconnecting on ignition cable, be sure to
hold the cable cap. If the cable is disconnected
by pulling on the cable alone, an open circuit might
result,
REPLACING OXYGEN SENSOR
‘The oxygen sensor is @ device which helps control the
fuel mixture. if the oxygen sensor is damaged, the
exhaust-gas cleaning efficiency as well as driveabilty de-
teriorates, Therefore, it should be replaced periodically
with @ new one,
FUEL SYSTEM
Tank, Lines And Connections
1. Check for damage or leakage in the fuel lines and
connections.
2, Inspect the surface of fuel hoses for heat and me-
chanical damage. Hard and brittle rubber, cracking,
tears, cuts, abrasions and excessive swelling indl-
cate deterioration of the rubber.
3, Ifthe fabric casing of the rubber hose is damaged by
‘cracks and abrasions in the fuel system, the hoses.
should be changed.
MANUAL TRANSAXLE (INSPECT OIL LEVEL)
Inspect for leakage in each component and check the cil
level by removing the filer plug. If the oil is contaminated,
replace it with new oil
1. With the vehicle parked at a level place, remove the
filler plug and make sure that the oil level is the
‘same level as the plug hole.
2. Check that the transaxle oil is not dirty,
TRANSAXLE OIL (REPLACE)
1. With the vehicle parked at a level place, remove the
magnetic plug and drain transaxle oil.
2, Replace the washer with a new one and reinstall the
plug.
8. Fill with transaxle oil (through the filler plug part)
Until the ol level Is the same level as the plug hole.
INSPECTING STEERING LINKAGE
1. Check the steering wheel freeplay.
Maximum steering whee! freeplay : 30 mm (1.164 in)
2. Check the steering linkage for looseness and dam-
age.
2) Tie rod ends must not have excessive play.
b) Dust seals and boots must not be damaged.
¢) Boot clamps must not be loose.
